1. Nifty Hr 15 Parts Manual

MODULAR GENERATOR SYSTEM OWNERS MANUAL MODELS#: HR-15 60 Hz HR-12 50 Hz 9991041 Rev. ® Smart Power Systems A. 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.

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. 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. ® Smart Power Systems A. 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. ® Smart Power Systems A. 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. 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. ® Smart Power Systems A. 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. 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. ® Smart Power Systems A. MODULAR GENERATOR SYSTEM Page 9 of 53 Figure 2.

® Smart Power Systems A. 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. ® Smart Power Systems A. MODULAR GENERATOR SYSTEM Page 11 of 53 System Specifications (cont.) Model of generator HR-15 HR-12 Fittings Dry Weight (without pump) 442 lbs. 34.5” L x 19” W x 22” H 34.5” L x 19” W x 22” H Dimension of Tray Asm.

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”. 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.

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. ® Smart Power Systems A. 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. 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.

® Smart Power Systems A. 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. 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.

Nifty Hr 15 Parts Manual

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. Smart Power Systems A. 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. ® Smart Power Systems A.

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.

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. ® Smart Power Systems A. 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. 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. ® Smart Power Systems A. 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. ® Smart Power Systems A. 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.

® Smart Power Systems A. 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.

® Smart Power Systems A. 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. If the Display looks like Figure 13, The purge option is enabled. 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.

® Smart Power Systems A. 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. ® Smart Power Systems A. 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). ® Smart Power Systems A. 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. ® Smart Power Systems A. 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.

® Smart Power Systems A. 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).

® Smart Power Systems A. 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. ® Smart Power Systems A. 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”.

® Smart Power Systems A. 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. ® Smart Power Systems A. 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. ® Smart Power Systems A. 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. ® Smart Power Systems A.

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 &. ® Smart Power Systems A.

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 &. ® Smart Power Systems A. 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. ® Smart Power Systems A.

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. ® Smart Power Systems A. 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. This indicates overheating or aging. Drain and flush the system.

Fill with new, clean hydraulic fluid. 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. 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. 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. GENERATOR, HR-15/80cc L, SPL PUMP 1500047C 851 2611015 GENERATOR, HR-15/80cc L, KEY PUMP 1500047C 851 2600615 GENERATOR, HR-15/80cc, R, SPL PUMP (THRU-DRIVE) 1500047C 851 2610615 GENERATOR, HR-15/80cc, L, SPL PUMP (THRU-DRIVE) 1500047C 851 2601615. 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. ® Smart Power Systems A.

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 . 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. While keeping the setscrew from rotating, with the hex wrench, re-tighten the. ® Smart Power Systems A. 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.

® Smart Power Systems A. MODULAR GENERATOR SYSTEM Page 53 of 53 Step c: After selecting Step a: Hold Mode until , Press On/Off until Amps Line 1 Blinks . Release switch so  appears.

Step b: Press mode twice to make .

Empire Comfort System Parts Manuals (heater parts): White Mount Hearth, Empire Heaters, Broilmaster Grills If you are in need of parts for your Empire Comfort System product we can help if you have the part number(s). To obtain the part numbers that you will need you can call Empire at 800-851-3153 and talk with a technician. If they can give you the part number(s) that you will need you can call us at 616-457-5867 with the part number(s) and we can look them up and give you pricing and availability. Or you can click on one of the products listed below.

The owners manual will open up in a PDF file and you can look at the parts breakdown to determine what parts you need to order. Call us at 616-457-5867 to order your Empire parts. Heater parts.