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Smart power HR-15 Owner's Manual

A.c. modular
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A.C. MODULAR
GENERATOR SYSTEM
OWNERS MANUAL
MODELS#: HR-15 60 Hz
HR-12 50 Hz
9991041 Rev. H

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Summary of Contents for Smart power HR-15

  • Page 1 A.C. MODULAR GENERATOR SYSTEM OWNERS MANUAL MODELS#: HR-15 60 Hz HR-12 50 Hz 9991041 Rev. H...

  • 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 ....................10 Pre-Installation Guide ..................... 12 Installation Guide ......................18 Hose Installation Guidelines ..................23 Operation .........................
  • 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

    A generator driven by a hydraulic motor delivers the electrical power. The motor turns at 1800 RPM for the HR-15, or 1500 RPM for the HR-12, as controlled by the flow of hydraulic fluid through an electrically controlled proportional valve. The proportional valve is directly driven by the system controller.
  • 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-15/HR-12 generator system Figure 1...
  • Page 9 OUTPUT GENERATOR BLACK CIRCUIT BREAKER WHITE/BLUE OUTPUT WHITE/RED WINDING A PURPLE/WHITE RED/WHITE WINDING B BLUE/WHITE FIELD LOGIC HI CIRCUIT BREAKER LOGIC LO ORANGE/WHITE FIELD WINDING GENERATOR BLACK PINK ASM, FIELD CONTROL BLUE P/N 3100308 Electrical schematic for HR-15/HR-12 generator system...
  • Page 10 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 9 of 53 Figure 2...

  • Page 11: System Specifications

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 10 of 53 System Specifications Model of generator HR-15 HR-12 Generator Type AC Inductive AC Inductive Speed 1800 RPM 1500 RPM Frequency 60 Hz 50 Hz Voltage 120/240 VAC 115/230 VAC...
  • Page 12 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 11 of 53 System Specifications (cont.) Model of generator HR-15 HR-12 Fittings Dry Weight (without pump) 442 lbs. 442 lbs. 34.5” L x 19” W x 22” H 34.5” L x 19” W x 22” H Dimension of Tray Asm.

  • Page 13: 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: K3VL80/B-10R A left hand rotating pump will have the letter “L”...
  • Page 14 Verify that the drive shaft selected will couple to both the PTO and the SPS ® supplied pump. Pumps supplied by Smart Power Systems for this system have an SAE C, 1.25” keyed shaft.
  • Page 15 Do not exceed hose lengths of 20 feet. Mounting considerations: The SPS models HR-12 and HR-15 have been specifically designed to be mounted on top of a vehicle, in the open, without requiring any additional coverings. Reference Figure 3, Figure 4, and Figure 5 for minimum clearances around the perimeter of the generator’s tray assemble.
  • Page 16 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 15 of 53 Bottom view of HR12/HR-15 tray assembly showing minimum clearance for proper ventilation Figure 3 End view of HR-12/HR-15 tray assembly showing minimum clearance for proper ventilation...
  • Page 17 Systems A. C. MODULAR GENERATOR SYSTEM Page 16 of 53 Figure 4 Left side view of HR-12/HR-15 tray assembly showing minimum clearance for proper ventilation Figure 5 WARNING: Do not mount the hydraulic pump, tray assembly or reservoir in any location that is not well ventilated.
  • Page 18 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 17 of 53 a. Locate a position to mount the SPS Command & Control Center. The ideal location for the Command & Control Center will be in an area that is easily seen and accessed by the generator operator.

  • Page 19: 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-12/HR-15 tray assembly Figure 7...
  • Page 20 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 21 Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 20 of 53 HR-12/HR-15 tray assembly disassembled into base tray assembly (with diamond plate cover added), cooler/fan enclosure and reservoir Figure 9 Mount Command & Control Center: a. Create hole pattern as shown in Figure 10.
  • Page 22 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 21 of 53 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 10...
  • Page 23 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-12/HR-15 tray assembly Figure 11 WARNING: Never operate the system with the pump case drain plugged. Damage to the pump seals will result.

  • Page 24: Hose Installation Guidelines

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 23 of 53 Hose Installation Guidelines Never install a hose without first flushing it with clean hydraulic fluid to remove any debris. Never install a hose in a location where it will rub against an abrasive surface or sharp edge or corner.
  • Page 25 A. C. MODULAR GENERATOR SYSTEM Page 24 of 53 Connect the vehicle’s breaker panel to the generator output. The HR-15 generator is pre-wired to supply 120/240 VAC, the HR-12 generator is pre-wired to supply 115/230 VAC. The generator frame is 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 26 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 25 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 27 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 53 WARNING: 12 volts DC must be directly applied to the generator system controller whenever the hydraulic pump is engaged. Failure to do so may cause excessive fluid temperature, damaging the system components and will void the warranty.
  • Page 28 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 27 of 53 Main power breaker Figure 12 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 29 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 53 Figure 13 1. If the Command & Control Center is dark, press the Mode switch to put the display into Normal mode. 2. If the Display looks like Figure 13, The purge option is enabled.
  • Page 30 A. C. MODULAR GENERATOR SYSTEM Page 29 of 53 Verify that the generator’s output frequency is 59-61 Hz (for HR-15) or between 49- 51 Hz (for HR-12). If the frequency is not within that range, contact Smart Power Systems at (231) 832-5525 for more information.
  • Page 31 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 30 of 53 Step b: Hold Mode until Amps Line 1 Blinks . Release switch so  and  appear. Step c: Press On/Off until the desired value appears Figure 15 Enabling Auto-Start Option a.

  • Page 32: Operation

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 31 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 Figure 16).
  • Page 33 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 32 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 34 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 33 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 35 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 34 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 36 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 35 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 37 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 36 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 38: Special Operating Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 37 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 39: Maintenance Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 38 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 40 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 39 of 53 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 41 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 40 of 53 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 42: Troubleshooting Guide

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 41 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 43 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 42 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 44 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 43 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 45 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 44 of 53 Verify there are no air bubbles in the fluid by viewing inside the reservoir. If there are air bubbles, check fluid level, tighten all fittings, and look for cracked fittings or hose leaks on the pump inlet line.
  • Page 46 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 47 The resistance between wires 1 and 2, and wires 3 and 4 should ® be essentially 0 ohms. Contact Smart Power Systems at (231) 832-5525 if any problems are found.
  • Page 48 The generator speed may be incorrect. The generator output should be between 59-61 Hz for a HR-15 or 49-52 Hz for a HR-12. If it is not, contact ® Smart Power Systems at (231) 832-5525 for further instructions.

  • Page 49: Sps Model Matrix

    GENERATOR, HR-15/80cc L, SPL PUMP 1500047C 8583055 8510107 9991041 2611015 GENERATOR, HR-15/80cc L, KEY PUMP 1500047C 8583055 8510102 9991041 2600615 GENERATOR, HR-15/80cc, R, SPL PUMP (THRU-DRIVE) 1500047C 8583055 8510124 9991041 2610615 GENERATOR, HR-15/80cc, L, SPL PUMP (THRU-DRIVE) 1500047C 8583055 8510125 9991041 2601615...

  • Page 50: Pump Adjustment

    Generated output frequency is “too low.” Verify output frequency when the vehicle is in fast idle and oil temperature is below 160F. If the frequency drops below 59Hz (for the HR-15) or 49 Hz (for the HR-12), the pump output flow may need to be increased.
  • Page 51 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 50 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 52 4mm hex wrench. Adjust the flow control until the generator’s output frequency is 63 Hz for the HR-15 or 55 Hz for the HR-12. d. While keeping the setscrew from rotating, with the hex wrench, re-tighten the...
  • Page 53 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 52 of 53 Pump assembly Figure 30 Disable the generator Pump Set option. After the pump has been properly adjusted, disable the Pump Set option by performing the following steps:...
  • Page 54 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 53 of 53 Step c: After selecting Step a: Hold Mode until , Press On/Off until Amps Line 1 Blinks .  appears. Release switch so  appears. Step b: Press mode twice to make ...

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