Real Power RP050 Bedienungsanleitung

OWNER’S MANUAL RP050 | RP075 | RP100

464 Southpoint Circle, Suite C

Brownsburg, Indiana 46278

(877) 670-7325

Fax (317) 275-9370

www.realacpower.com

For customer assistance, please call (877) 670-7325

2 of 25 Rev. 22-05

TABLE OF CONTENTS PATENTED DEVICE ........................................................................................................................... 3

LIMITED WARRANTY ....................................................................................................................... 3

OWNER’S RESPONSIBILITIES ........................................................................................................... 4

LIMITATIONS ................................................................................................................................... 4

SAVE THIS MANUAL ........................................................................................................................ 5

SAFETY WARNINGS AND PRECAUTIONS ......................................................................................... 6

ELECTRIC GENERATOR SAFETY PRECAUTIONS AND WARNINGS .................................................... 7

COMMON SENSE AND CAUTION PREVAIL ...................................................................................... 7

REAL POWER SYSTEM OVERVIEW .................................................................................................. 8

RP050, RP075, & RP100 - MECHANICAL REFERENCE DIAGRAM .................................................... 9

RP100 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM ................................................... 10

RP100 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM (INTERNAL) ............................... 11

RP050, RP075, & RP100 ELECTRICAL LIMITATIONS AND CAPABILITIES ....................................... 12

DSR REGULATOR DIAGRAM .......................................................................................................... 13

OPERATION ................................................................................................................................... 14

MAINTENANCE .............................................................................................................................. 16

TROUBLE SHOOTING ..................................................................................................................... 24

ENVIRONMENTAL IMPACT ON ELECTRICAL PERFORMANCE ....................................................... 25

UNAUTHORIZED AND UNTESTED USE - MISUSE ........................................................................... 25

artwork contained herein may be reproduced in any shape or form without the express written consent

of Contour Hardening, Inc. is a trademark of Contour Hardening, Inc.

Rev. 22-05 3 of 25

PATENTED DEVICE

The following patents issued by the United States Patent and Trademark Office cover the Real Power 

chassis integrated AC generation system and/or the methods for using it:

US Patent # 6,979,913

US Patent # 7,057,303

Patent Application 2021/0316617 A1 filed 10/14/21

LIMITED WARRANTY

Contour Hardening Inc. (CHI) hereby warrants to the Purchaser of the Real Power™ chassis integrated

AC generator system (SYSTEM) that the System will be free of defects in material and workmanship from

the date of installation marked on the warranty registration card or other written documents that

independently collaborate the installation date. If the installation date cannot be verified the warranty

will begin 30 days after the date of shipment from CHI as follows:

All rotating parts and components: 1 year

Electrical Distribution-Outlet box and components therein: 1 year

Repair or replacements parts: 90 days*

Paint or coating on all components: NOT WARRANTED

PROVIDED that the System is operated in accordance with the operating instructions included with all

shipments. CHI may require reasonable proof of date of purchase. THEREFORE PURCHASER SHOULD

RETAIN THE SALES RECEIPT OR INVOICE.

Defective parts must be returned to CHI for inspection before they can be covered under this warranty.

Parts or a System returned to CHI without prior authorization will not be accepted. After CHI confirms

the defect and approves the warranty claim, CHI will authorize the replacement of the defective part(s).

For confirmed and approved warranted repairs, CHI will pay for the parts to repair or replace the

defective parts or System. CHI will not pay for labor to disassemble or reassemble the System unless

the system was installed by CHI and it is still under warranty. Systems installed by CHI must be repaired

by CHI in Indianapolis, Indiana for disassembly and reassembly to be covered under warranty.

CHI retains the right to make ALL subjective decisions regarding warranty claims.

Labor to repair or replace parts will occur only during normal business hours, overtime to expedite

repair or replacement will not be covered under warranty.

Any and all labor provided by the purchaser, an agent of the purchaser or any other party other than

CHI, either during the original installation or repair, is not covered under CHI’s warranty.

* Repair or replacement parts are also warranted for ninety (90) days from the date of shipment from

CHI. Any part repaired or replaced during the warranty period assumes the remainder of the original

System warranty or ninety (90) days, whichever is greater.

4 of 25 Rev. 22-05

OWNER’S RESPONSIBILITIES

Purchaser is obligated to operate and maintain the System in accordance with the recommendations

and instructions contained herein. Purchaser is responsible for the costs associated with such use,

maintenance and adjustments that may be required.

All warranty claims must be brought to CHI’s attention within a reasonable time, preferably within thirty

(30) days, after discovery that the System fails to meet this warranty.

Purchaser is responsible for payment of any of the following expenses that might be incurred as a result

of a failure under the terms of this Limited Warranty:

1. Shipping or delivery to Real Power for vehicles or parts covered under this warranty;

2. rental equipment used to replace the System or the vehicle on which the System is mounted

during the time the System and vehicle are being repaired;

3. telephone and other communication expenses;

4. living and travel expenses;

5. the premium costs for overtime labor requested by the Purchaser to expedite the repair;

6. the cost of airfreight or other extraordinary expenses for shipment of parts over and above

premium surface transportation;

7. failures due to normal wear or excessive wear, lack of reasonable and necessary maintenance,

accident, misuse, abuse, negligence in operation or maintenance, unauthorized modifications or

repairs, use of add-on or modified parts not supplied by CHI, improper storage, vandalism, and

improper installation or improper maintenance or service;

8. transportation of vehicle to designated repair facility; and

9. failures due to electrical overload or short circuits.

LIMITATIONS

This Limited Warranty shall be limited to the repair or replacement of parts that prove defective under

normal use and service and which upon examination shall indicate to CHI’s satisfaction they are

defective. This Limited Warranty will not cover repair where normal use has exhausted the life of a part

of the System or the entire System. Like all other mechanical devices, this System needs periodic parts

replaced and service to perform well. The service life of the System is dependent on the care that it

receives and the conditions under which it operates. Extreme heat and/or dusty or dirty conditions can

cause excessive wear. EXCESSIVE WEAR, when caused by improper maintenance or operation, is NOT

COVERED by this Limited Warranty.

Use of this System on a vehicle used for snow removal causes excessive wear and is not covered under

this warranty.

This Limited Warranty does NOT cover any failures or operating difficulties due directly or indirectly to

normal or excessive wear, collision, negligence or accidents, abuse, misuse, unauthorized modifications

– alterations – or the use of add-on or modified parts not supplied by CHI, vandalism, improper

installation or improper maintenance or service, or failure to perform normal and routine maintenance.

Deterioration or damage due to severe weather conditions such and hurricanes, earthquakes or

tornadoes and exposure to corrosive chemicals either direct or in the atmosphere, is not covered by this

Limited Warranty. Damage associated with ground clearance under the vehicle is not covered by this

Limited Warranty.

Rev. 22-05 5 of 25

THERE ARE NO OTHER EXPRESS WARRANTS and any applicable implied warranties of merchantability

and fitness for a particular purpose are limited in duration to the period of coverage of this express

written Limited Warranty. TO THE EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIIED WARRANTIES

ARE EXCLUDED. Some regions do not allow limitation on how long an implied warranty lasts, so this

limitation may not apply to Purchaser.

CHI is NOT LIABLE for any special, incidental, indirect, contingent, or consequential damages arising

from the use of the System. Some regions do not allow limitation or exclusion of incidental or

consequential damages, so this limitation may not apply to Purchaser.

This Limited Warranty gives you specific legal rights. You may also have other rights that may vary from

state to state or province.

CHI does NOT authorize any person or company to assume for it any other obligation or liability in

connection with the sale, installation, use, removal, return, or replacement of its equipment; and no

such representations are binding on CHI.

CHI MAKES NO REPRESENTATION OR WARRANTY OF ANY KIND TO THE PURCHASER THAT HE OR SHE IS

QUALIFIED TO MAKE ANY REPAIRS TO THE SYSTEM OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY

PARTS OF THE SYSTEM. THE PURCHASER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER

REPAIRS TO THE SYSTEM OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER

INSTALLATION OF REPLACEMENT PARTS THERETO.

THIS LIMITED WARRANTY ONLY APPLIES TO SYSTEMS SOLD AT RETAIL.

SAVE THIS MANUAL

You will need the manual for the safety warnings and precautions, assembly instructions, operating and

maintenance procedures, parts list, and diagram. Keep your invoice with this manual. Write the invoice

number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future

reference.

6 of 25 Rev. 22-05

SAFETY WARNINGS AND PRECAUTIONS

When using Real Power, basic safety precautions should always be followed to reduce

the risk of personal injury and damage to equipment.

Read all instructions before using this system!

1. Observe work area conditions. Do not use electricity or power tools in damp or wet locations. Keep

work area well lighted. Do not use electrically powered tools in the presence of flammable gases or

liquids.

2. Keep unauthorized personnel and children away from the vehicle. The Real Power system contains

rotating components and lethal voltages. Only trained personnel should be allowed near the vehicle

while the system is operating.

3. Lethal voltage is present whenever the system is operating. Real Power generators can produce

voltages in excess of 480V.

4. Dress properly. Do not wear loose clothing or jewelry as they can be caught in

moving parts. Protective, electrically non-conductive clothes and non-skid footwear are

recommended when working. Wear restrictive hair covering to contain long hair.

5. Do not go under vehicle when System or engine is running. Do not work on or near

an exposed shaft while the engine is running.

6. Do not overreach. Keep proper footing and balance at all times. Do not reach over or across running

machines.

7. Do not start or stop the generator with a load connected. Unplug connected tools, appliances and

cords when not in use and prior to starting or stopping the System.

8. Check for damaged parts. Before using the Real Power system inspect it thoroughly. Make sure all

bolts are tight. The generator should be dry and free of debris.

9. Replacement parts and accessories. When servicing, use only identical replacement parts. Use of

any other parts will void the warranty. Replacement parts and service are available from Real Power.

You contact us by calling (877) 670-7325. Parts and accessories should be installed by qualified

technicians.

10. Do not operate a Real Power system if under the influence of alcohol or drugs. Read warning labels

on prescriptions to determine if your judgment or reflexes are impaired while taking drugs. If there

is any doubt, do not operate the system.

11. Use proper size and type cable. Follow Local and National Electric Code guidelines when connecting

loads to the generator.

Rev. 22-05 7 of 25

ELECTRIC GENERATOR SAFETY PRECAUTIONS AND WARNINGS

When System is operating, lethal voltage is present!

1. The generator produces electrical current. Improper use can result in electrocution, injury or death.

Only a qualified technician should service or repair this generator.

2. The generator was designed to be used in a dry area. Use extreme caution when operating the

System in rain, snow, sleet, or damp conditions. Operating the System in such conditions is NEVER

recommended or encouraged. Moisture can carry electrical current and could cause electrocution.

3. If the generator is connected to a building, home, business, or any other electrical circuit normally

fed by utility power, steps must be taken to ensure that the generator output and the utility power

are isolated. Failure to isolate the systems could result in personal injury or death to those working

around these circuits. Any connection in this regard must only be done in accordance with NEC or

the locally applicable Electrical Code .

4. Do not exceed the generator's rated capacity. The total electrical loads must be added to determine

the total electrical load. If the electrical appliance does not list the wattage rating, you can calculate

it by multiplying amps times voltage (amps x voltage = watts).

5. Do not tamper with the drive engine-governed speed. The generator is designed to operate at a set

speed. Changing this speed will change the output voltage and frequency. Increases in speed will

damage rotating parts of the generator. Slower speeds may damage the generator or appliances

connected to the generator due to low voltage.

6. Always follow national and local safety codes.

7. Do not start or stop the System with equipment connected and turned on.

8. Do not operate your Real Power equipped vehicle in an enclosed area due to the carbon monoxide

fumes produced. The fumes are colorless and odorless and are deadly.

9. Never handle electrical equipment or cords while standing in water.

10. Only use 3-prong, grounded extension cords.

11. Keep fingers, hands, cords and other loose items away from the spinning shafts and pulleys that are

rotating under your Real Power equipped vehicle.

12. Never refuel or add fuel to your vehicle or remove the fuel cap whenever the System is operating.

13. Read, understand, and follow all safety precautions in your vehicle owner’s manual prior to running

the System.

COMMON SENSE AND CAUTION PREVAIL

The warnings, cautions, and instructions discussed in this manual cannot cover all possible conditions

and situations that may occur. It must be understood by the operator that common sense and caution

are factors that cannot be built into this product, but must be supplied by the operator.

8 of 25 Rev. 22-05

REAL POWER SYSTEM OVERVIEW

Real Power generator systems are manufactured exclusively for use with the power take off (PTO) of a

Class 4 or larger work tuck with diesel engine and automatic transmission. While in a parked, stationary

mode, the engine of the truck provides rotational power to the generator via the PTO attachment,

turning it at a constant 1800 RPM to produce 60Hz. The truck engine RPM, power output, and torque

are controlled automatically by the truck ECM and TCM with no input required from the user.

Power from the generator is typically routed to a remote electrical panel box, located in the body of the

truck, which contains both the low voltage DC control signals and the high voltage AC power distribution

with main breaker, sub breakers, and either plug-in receptacles or hard wire lines for other equipment.

With the exception of specially ordered, dedicated 240/120V-only systems, the generators provided by

Real Power have an industry-standard 12 wire reconnectable configuration, capable of 480V 3Φ, 208V

3Φ, or 240/120V 1Φ depending on how they are tapped. All Real Power generators are equipped with a

proprietary set of enhancements to make them robust against difficult road environments.

A diagram showing the connection options is provided with each system. All connections to the

generator should be done in accordance with NEC guidelines and any other applicable electrical code for

your area.

Rev. 22-05 9 of 25

RP050, RP075, & RP100 - MECHANICAL REFERENCE DIAGRAM

Notes:

1. This diagram is intended to help the reader familiarize themselves with the generator mechanicals. There is some variability between trucks depending on model year,

wheelbase, and body style.

2. 4x4 Vehicles have an added Live Drive transfer case adapter (not pictured here) allowing the drive shaft to pass through.

10 of 25 Rev. 22-05

RP100 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM

Notes:

1. This diagram is intended to help the reader familiarize themselves with the standard Real Power electrical panel. Exact design will vary by generator size and specification.

Always take care to use proper electrical safety procedures when using any connection panel.

2. To reset E-Stop, pull red knob out.