Robin RGX1800, RGX2400, RGX3500, RGX5500 User manual

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Model
RGXl80
RGX35OOlR
evised]
I ISSUE EMD-GS0597B 1
--
CONTENTS
Section
Title
Page
1. SPECIFICATIONS
....................................................................
1
2.
PERFORMANCE CURVES ...............................................................
3
2-1 Model RGX1800
.......................................................................
3
2-2
Model RGX2400 ....................................................................... 5
2-3
Model RGXCJ500 .......................................................................
8
2-4
Model RGX5500 ...................................................................... 11
2-5
DC OUTPUT ..........................................................................
14
3. FEATURES
.................................................................................
15
4.
GENERAL DESCRIPTION OF THE GENERATOR ................................. 16
4-1
External View of Generator .......................................................... 16
4-2 Control Panel
......................................................................... 17
4-3 Location of Serial Number and Specification Number .............................. 31
5.
CONSTRUCTION AND FUNCTION.. ..................................................
32
5-1
Construction
..........................................................................
32
5-2
Function ...............................................................................
32
5-3 Description of Generator Operation
................................................. 36
6.
SAFETY PRECAUTIONS ................................................................ 39
7.
RANGE OF APPLICATIONS ............................................................
40
8.
MEASURING PROCEDURES
..........................................................
43
8-1
Measuring Instruments ...............................................................
43
8-2 AC Output Measuring
................................................................
46
8-3 Measuring Insulation Resistance
.................................................... 46
9. CHECKING FUNCTIONAL MEMBERS
...............................................
48
9-1 Pilot lamp
.............................................................................
48
9-2 AC Receptacles
......................................................................
48
9-3 Circuit Breaker
........................................................................
49
9-4
Stator .................................................................................. 49
9-5 Rotor
.................................................................................. 50
9-6 Condenser
............................................................................
50
9-7 Diode Rectifier ........................................................................
51
10. DISASSEMBLY AND ASSEMBLY
..................................................... .52
10-1 Preparation and Precautions
........................................................ 52
10-2 Special Tools for Disassembly and Assembly
....................................... 52
1 0-3 Disassembly Procedures
.............................................................. 53
1 0-4 Assembly Procedures
................................................................ 61
10-5 Checking, Disassembly and Reassembly of the Control Box ...................... 68
Section
Title Page
11. TROUBLE SHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
11-1
No AC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
11-2
AC voltage is too high or too low
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
11-3
AC voltage is normal at no-load, but the load cannot be applied. . . . . . . . . . . . . . . . . . . . . . . . . .
72
11-4
No DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
11-5
Idle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
12. WIRING DIAGRAM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
I
-L
I
Model
Type
.
Frequency -.
.-_ _ -. . ..-_.----
Maximum Output
Rated Output
Rated
Voltage
Current
-.- _..._
Power Factor
_.._. - -.-.---
DC Output
Voltage Regulator -
Voltage Regulation
Type
_ __ _. _.
Model
--- .----.- _- -., . . . -_ ..---
Displacement
Rated Output
_.,--. --.. -,- . ..-.-.._ _...---..-
Fuel
_-~_-..-..-.- . . .
Fuel Tank Capacity
-.-_. -. .-
Fuel Consumption Ratio
(at Rated Output)
- .
‘-
._.
Oil Capacity
.,.. . . -, -__. ._., -.,---
Starting System
Dimensions L
X
W
X
H
-.._-._ _.. .._. . . --
-_. -------
Drv Weight
45 kg (97 Ibs.)
RGXI 800 RGX2400
__-_--_. -.. .,_ _
----. ,,. -.
. _. _, _ _ _
---
Brushless, Revolving Field, Self-Exciting, 2-Pole, Single Phase
.-
.- - ._.
--- . ..-. ..----
.-- .-
50Hz
60Hz 50Hz 60Hz
--..--.- ., -. ,_. -
.-
15oow 18OOW
2ooow
2400W
-. --_-
1300w ---
..- --.-. ., _-- ---._--.... ., ..--
15oow 17oow
2ooow
--_ ,- -- -.
13.6A 11ov
--,-.
12.5A 2;OV --.
----
---_. ..- -
- -- .._ -
6.8A
240V ‘.-
-.-.- _--_ --- I. ---- -. ,.-
13.6Al6.8A 11 OVl22OV
_---_. .-
- --.-..... -
._-.- .,
12OV/24OV 12.5Al6.3A .-~ -- .i--
. .._ -_---__A._. --.. ._ .--
-.. .-_-.. . _--.
1 .o
.-
.--. _ -~ _._..,,,, ,---- _._,. -
- . --._ .-_-. ..--
12V-8.3A (1 OOW)
-- . .
__--_- . ,-_-- __,... __ ..- --_ ,.,... --. . __
- ,.
Condenser Type
..- .-
_ ..- -..-_ ..--..., .._~__ _,- ,..
- ---.-.,-I- -.,. .-
Within 10%
--.-. ..---_- ..__. --.-._- ..-- .-.....- -._-..- _,._
Robin Air-Cooled 4-Cycle Gasoline Engine
- _ ---_ .._-
EY20D
-- . . . - _ .___
;83 cc (11.17 cu. in.)
--.
-_ . .,. _..-- ..-._.. .-.-- ..-. - -.
3.5 HP13600 rpm
_.-- ..,. .-. --
.- . .
Automobile Gasoline
_ - . - ..-.-.._.,. ---_ .._
10 lit&s (2.64 U.S. gal.)
._.----. ..-. - .-..
.-- - _._-.- -.
600 cc
--. .-,. ., . ..--~.-. .- .-._ --- ,_-
Recoil Starter
._. -. .,._ ----.-- _ ._- .., .
552
X
377 X 482 mm
(21.7 X 14.8 X 19.0 in.)
-
- ..- ..--
---
45.5 kg (100 Ibs.)
-.-. .-
I
N
I
Model
.-- ._ ,,--. -- . . _.___
le
Frequency
--- _.-,.... - _...-_
Maximum Output
Rated Output
Voltage
. . .._-
._..--.. .,._,
Rated
Current
Power Factor
--_ _ ._.. . __--_.. __.___ -
DC Output
- --- .
Voltage Regulator
~--- .~ . _-.-_
Voltage Regulation
--,.,._- - -.., .-
Type
..-_ -- .____. -._. _
Model
---.- . ,,, .-- ._.. --.
Displacement
Rated Output
. . .-._- . . .
Fuel
__
,,
----- - -,,._- -
Fuel Tank Capacity
- .-.
Fuel Consumption Ratio
(at Rated Output)
Oil Capacity
.--- -,..
-. -_ ,. __-
Starting System
-... -- --___
Dimensions L x W x H
- -.. .-
Dry Weight
--
.
_ ._
.._
-. _
-
RGX3500
RGX5500
--. .._._ --.-
Brushless, Revolving Field, Self-Exciting, 2-Pole, Single Phase
- . ,..,.. -_---._. .___ _.
---.--- . ..- - ._.. _.-
-- -.---- --.-. -..-----
50Hz 60Hz 50Hz 60Hz
-_ ._.
3ooow .--
--. _ ,.._. -. -.-- --
3500w 5ooow 5500w
-.-.-.--~.. ____
-_---- ..-- -_
2500W
3ooow
4400w 4800W
- -,,....- -_ ---- - .--.-... ---
--- -_-----
-.--
11ov 22.7A 1lOV
26.4A
1lOV
40A
1lOV
43.6A
---------.---
220v 11.4A 12ov
24.2A -
220v
20A
12ov 40A -
.---,-- -...-- -
240V
10.4A
‘-220v 13.2A 240V -.
18.3A
220v 21.8A
-..-_-, -
-_._-_-
11 OVl22OV 22.7Al11.4A 11 OVl22OV 26.4Al13.2A 11 OVI22OV 40Al20A
11 OVi22OV 43.6A121.8A
_., _ _-..
--.. -..
.- .-
-_
-
12OVl24OV 24.2Al12.1A - -’ -
12OVI24OV 40Al20A
-..- _--__-- __._ ,, .,
-,. .---. .-
-.----- --.-
1.0
_-_.._. . ,. . .~- _______
-.-,. ---- -..-_
12V-8.3A (1 OOW)
..---... .____ _
-.- ---,-.
--.------. -_--
Condenser Type
-.-.- ._. _- -.- ---.... - --.-- - .-.-., -_ .__.. -. ..-._ --._.--
Within 10%
----- .~--___ ____-
- --..,... --
Robin Air-Cooled 4-Cycle Gasoline Engine
--._ - .- _ _ - _._-
----
EY28D EY40D
,,,. .-
--.-_ --..--, _.--
273 cc (l-6.66 cu. in.)
---- ..--.-._ - -.-,.- --
388 cc (23.68 cu. in.)
. . .__--
._ ..-.. .._-
------. ._- ,- ,-.. --. .._-
5.5 HP/3600 rpm
8.0 HP/3600 rpm
~ .--...
.--~ ____ --___
------- -.,.. -----
Automobile Gasoline
,. _ -.---.-
_.--.-
13 liters (3.43 U.S. gal.)
15.5 liters (4.10 U.S. gal.)
- ,_. -.--,_
.- .-..,. --
--.-_--_-_---,--- . ..---. ---.---_--- -...- -
50Hz: 1.8 liters/hour
50Hz: 2.7 liters/hour
60Hz: 2.1 liters/hour
60Hz: 3.1 liters/hour
-..-- ___
85Occ - -.
. ._ . ..-.. -- --
1200 cc
- ._
._-.-... ___
-.-- .-. .-. .-_------
Recoil Starter and Optional Electric Starter
-.-. . . ..-.- ---.---- . .._.. ..-.. -.-- ~---.-----
552 X 413 X 520 mm
635 x 448 X 596 mm
(21.7
X
16.3
X
20.5 in.) (25.0 X 17.6 X 23.5 in.)
.-.. . .-_ ..-. --_-- -
-_
56 kg (123.5 Ibs.) 76 kg (167,6 Ibs.)
2. PERFOMANCE CURVES
2-l MODEL RGX1800
t
0
2 4
6 8 10
12 14
CURRENTIAI-
RGXl800
Output Max.
...................... 15(-J(-jw
Rated
.....................
13oow
JZpqueacy
........................
50Hz
Voltage
...........................
ll()V
0 3
6 9 12
15
CURRENTcAl-
62
60
I
i
.
.
I / ,
I I 1
0 3
6 9 12
15
CURRENT(A)-
RGXI 800
Output Max.
......................
18OOW
Rated
.....................
15oow
Frequency
........................
60Hz
Voltage
...........................
1lOV
RGXI 800
Output Max.
......................
18O()W
Rated
.....................
15oow
Frequency
........................
60Hz
Voltage
...........................
12ov
-3-
i I
‘-1 i
Llk 5
t
0.5k 0’
0
2 3 4 5 6
7
CURRENT IA) +
62
61
60
59
240
5
2
Li.l..ll:lil,
j :
0 3 6 9
CURRENT iAi __)
0
1
2 3 4
5 6 7
2k
RGXI 800
Output Max.
......................
15oow
Rated
.....................
13o()w
Frequency ........................
C&Hz
Voltage
...........................
22(Jv
RGXI 800
Output Max.
......................
18()(-jW
Rated
.....................
15()ow
Frequency ........................
60Hz
Voltage ...........................
22OV
RGXI 800
Output Max.
......................
15o()w
Rated
.....................
13(-J()w
Frequency
........................ 50Hz
Voltage
........................... 24oV
CURRENT IA1 __+
-4-
I
52
x 51
I
z 50
2 49
u
; 240
3 110
: 100
a
k
d 0 2 4 6 6 10 12 14
,
CURRENT IA)-
t
FREQUENCY 122OVt
62
7 61
I
z 60
z
u!
59
i
a:
u. 240
220
? 200
I
5 120 _
bj
a 110
c
2 100
5
0 3 6 9 12 15
CURRENT IAl-
2-2 MODEL RGX2400
?
0
4 6
12
16
20
2k
t
1.5k
4
I
L
0
t
2k
t
lk
z
RGXl800
Output Max.
...................... 15oow
Rated
..................... 13oow
Frequency ........................ 50Hz
Voltage
...................... 11 (y//22()v
RGX1800
Output Max.
...................... 180(34/
Rated
..................... 15oow
Frequency
........................
60Hz
Voltage
......................
11 ov/22ov
RGX2400
Output Max.
......................
2(-J)ow
Rated
.....................
17oow
Frequency
........................
50Hz
Voltage
...........................
11ov
CURRENT (A)-
-5-
/ i
I
I
E
I
2 !
! i 1
,
i i i I I ’ 1
1
II I i.. 11 ; l l ‘I
s
>
0
4
8
12
16
20
c-ll!?RFh!T iA:-
52
51
50
49
240
220
200
!
j ’
(
0
2
4
6
a
10
RGX2400
Output Max.
......................
24mw
Rated
.....................
2-Joow
Frequency..
......................
60Hz
Voltage
...........................
11(-g/
RGX2400
Output Max.
......................
2400~
Rated
.....................
2o(-Jow
Frequency..
......................
60Hz
Voltage
...........................
12ov
RGX2400
Output Max.
......................
24oow
Rated
.....................
2()oow
Frequency
........................
50Hz
Voltage
...........................
22ov
CURRENT (A)-
-6-
1 I ! i ’ I
I
VOLTAGE I
I
I
.g
, I ,
I ,
1 I
0
2 .I
6 8
10 12
5
CURRENT IA)-
.
x
r
1_ 52
51
i:
z
w 50
3
0 49
Y
31
u.
t 260
240
5
u, 220
‘3
a
!I
2
0
2 4
6
a
10
CURRENT (A!-----)
I I
I I
FAE&JENCY i22OV!
I
52
51
50
49
240 + 240
222
200
222
200
) +LT+E:,22+ )
(
1
2k
RGX2400
Output Max.
......................
24oow
Rated
.....................
2()oow
Frequency..
......................
60Hz
Voltage
...........................
22ov
RGX2400
Output Max.
......................
2o(-Jow
Rated
.....................
17oow
Frequency
........................
50Hz
Voltage
...........................
24ov
RGX2400
Output Max.
......................
2ooow
Rated
.....................
17OOW
Frequency
........................
50Hz
Voltage
......................
11 (y//22(-y/
0
4 8
12 16
20
CURRENT
(A) -
-7-
FREQUENCY 1220v)
1 *
1
I . I I I
i I
0
4
e
12
16
20
CURRENT iAi __)
2-3 MODEL RGX3500
I
I
T
=
-3k
c 52
2
w
51
2 50
C2K
t
L
z
u
49
c
LL
2
t
-1k k
120
2
0
Y 110
1 10s
-0
3
I 1
a
:
I
i
;
1 I
J
0
C 10
20
30
>
CURREilT IA. __)
I 1
I I
I
d
! I I
t
4k
3k
(
t
z
2k 5
1 lk E 2
0
RGX2400
Output Max.
......................
24()Ow
Rated
.....................
2-)(-jOw
Frequency
........................
fjo,-,z
Voltage
...................... l~()V~~OV
RGX3500
Output Ma. ......................
300Ow
Rated
.....................
25oow
Frequency ........................
50Hz
Voltage
...........................
1lOV
RGX3500
Output Max.
......................
35oQw
Rated
.....................
3o()ow
Frequency
........................
60Hz
Voltage
...........................
11ov
,
CURRENT (At __t
-8-
t
I
3
z
cl
6
I-
<
t
I
-z
I
62
61
60
59
130
120
110
0
10
20
30
CURRENT (Ale
I ! ! I ! I ! !
! ! ! I ! I I
52
51
50
49
240
220
200
0
4
8
:2
>
CURRENT (A!-
3k
t
2k j
s
i 2
I
T
63
I i 1 1
I !
4k
z
v
-
62+: ! I
, E:
RGX3500
Output Max.
...................... 35(-j()w
Rated
..................... 3()o()w
Frequency
........................ fj0t-j~
voltage
........................... 12ov
RGX3500
Output Max.
...................... 30@#
Rated
..................... 25oow
Frequency
........................ F&Hz
Voltage
...........................
220v
RGX3500
Output Max.
......................
3500w
Rated
..................... 30()@4/
Frequency
........................ 6(-JHz
Voltage
...........................
220v
CURRENT (A\) d
-9-
t
3
62
61
t
4k
5
60
5
2
59
3k
t
2
260
I
LL
3
f
240
2k ;:
220
3
1
lk
I
0
30
CURRENT (A) +
2-4 MODEL RGX5500
CURRENT (A\-
5k
62
61
60
59
i ’
I ’
;
120
110
100
RGX3500
Output Max.
......................
35oow
Rated
.....................
3()o()w
Frequency
........................
60Hz
Voltage
......................
12ov/24ov
RGX5500
Output Max.
......................
5ooow
Rated
.....................
44OQW
Frequency
........................
50j.j~
Voltage
...........................
11ov
RGX5500
Output Max.
......................
55o()w
Rated
.....................
4@-Jow
Frequency
........................
60Hz
Voltage
...........................
11ov
CURREXT iAld
- 11 -
62
61
60
59
i 1 ,
130
120
1’0
0 5
10 15 20 25
CURRENT (Al----)
I ( I ’
) 1 ( I 1
1
0 5
10 15 23 25
CURREUT IA!------)
1
I lk
2
‘2k z
t
5
I
lk 0
LO
‘i :I:;;
z
I I I I
I. I I I.
5 0 10
20 30 40 50
CURRENT (A;----)
RGXSSOO
Output Max.
......................
5oo(-jw
Rated
.....................
48()@‘,/
Frequency ........................
60Hz
Voltage
...........................
12ov
RGXSSOO
Output Max.
......................
5o(-Jow
Rated
.....................
44()()w
Frequency..
......................
50Hz
Voltage
...........................
22OV
RGXSSOO
Output Max.
...................... 55oow
Rated
..................... 48(-J&j/
Frequency
........................
60Hz
Voltage
........................... 22ov
- 12-
I
I
?-
G
I
0
5
10
15
20
25
CURRENT (A,-
t
52 52
51 51
so so
49 49
2:
240 240
220
200
120
110
100
0
10 20
30 40
so
CURRENT (Al -
62
61
60
59
240
L
VOLTAGE 1220V1
I
I
0
10 20 30 40
50
CURRENT iAl ___)
1
Sk
-4k t
-3k 2
;r
3
2
-2k 2
c lk
- 6k
- 5k
-4k t
I
t
2
3k ;:
z
Zk 5
0
t
lk
0
RGXSSOO
Output Max.
......................
5o()(y#
Rated
.....................
44oow
Frequency ........................
5(-~Hz
Voltage
...........................
240V
RGXSSOO
Output Max.
......................
5OO()W
Rated
.....................
44(-J)w
Frequency ........................
50Hz
Voltage
......................
11 ov/22()v
RGXSSOO
Output Max.
......................
55OOW
Rated
.....................
48()()W
Frequency ........................
fj(-)Hz
Voltage
......................
11 ov/22(y/
- 13-
( 1 I ( I : ( [ ( 1 !
’ I FRFnl:Fk’rY
f?40Vi
I ’ i
0 10 20
30 40
50
CURRENT
(Al
-
2-5 DC OUTPUT
18
> 16
z
cl 14
z d 12
> 10
CURRENT (Al-
l
5k
L4n
i t
3
‘3’< ‘-
3
0
k
RGXSSOO
Output Max.
...................... 55oow
Rated
..................... 48()&I,/
Frequency
........................ 60Hz
Voltage
...................... 12oVj24oV
DC Voltage
........................
12~
DC Ampere
........................ 8.3A
DC output
........................
lO(yJ/
The voltage curve shown in the left indicates the
characteristic of DC output when charging a battery.
The voltage
may
be decreased by 20% when the
resistance load is applied.
NOTE: It is possible to use both DC and AC out-
puts simultaneously up to the rated output
in total.
- 14 -
3. FEATURES
3-1 BRUSHLESS ALTERNATOR
Newly developed brushless alternator eliminates troublesome brush maintenance.
3-2 CONDENSER TYPE VOLTAGE REGULATOR
A trouble free condenser type voltage regulator ensures a stable voltage under all working
conditions.
3-3
OIL SENSOR
Oil sensor automatically shuts off the engine whenever the oil level falls down below the lower limit
to protect the engine from seizure.
3-4 QUIET OPERATION
Robin RGX series generator delivers a quiet operation with :
l
A large super silent muffler.
l
A quiet 4-stroke Robin engine.
l
A silent cyclone air cleaner.
3-5 NO RADIO NOISE
Noise suppressor spark plug and spark plug cap are equipped standard to prevent radio frequency
interference.
3-6 LARGE FUEL TANK
The large fuel tank allows more than 5 to 10 hours of continuous operation which is sufficient for a
half day or one day work without refueling.
3-7 RUGGED TUBULAR FRAME
Full cradle type rugged tubuler frame protects the generator all around.
3-8 COMPACT AND LIGHT WEIGHT
Newly developed brushless alternator enabled the RGX generators to be very compact in size and
light in weight.
3-9 MINIMAL MAINTENANCE
l
A brushless alternator release the operator from periodical brush maintenance.
l
A trouble free condenser type voltage regulator.
l
A drip-proof alternator design.
l
No-fuse circuit breakers.
l
An electronic pointless ignition system.
l
A dust-proof cyclone air cleaner.
3-10 LONG-LIFE DURABILITY
The heav-duty 4 stroke Robin engine and virtually maintenance-free brushless alternator ensure
greater durability with :
l
A brushless alternator with a condenser voltage regulator.
l
Full rubber mount in a sturdy tubular frame.
l
A forged steel crankshaft supported by two main ball bearings.
l
A pointless electronic ignition system.
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A cast iron cylinder liner.
l
A forged aluminum connecting rod.
- 15 -
4. GENERAL DESCRIPTION OF THE GENERATOR
4-1 EXTERNAL VIEW of GENERATOR
FULL POWER SWITCH
(DUAL VOLTAGE TYPE)
IDLE CONTROL SWITCH
(Option)
AC RECEPTACLE
3
DC FUSE HOLDER
---I-
4
DC OUTPUT TERMINAL
VOLTMETER
NO FUSE BREAKER
(PI LOT LAMP)
(RGXl800.2400: CIRCUIT BREAKER)
/
/
I
/
/
I .
/
CHOKE LEVER
, AIR CLEANER
1 RECOIL STARTER
1 MUFFLER
EARTH (GROUND) TERMINAL
FUEL C&K
PLUG COVER (SPARK PLUG, INSIDE1
.
TANK CAP
/
FUEL GAUGE
STOP BUTTON
\
OIL SENSOR UNIT
(Option)
OIL FILLER CAP-
FUEL TANK
DC FUSE HOLDER
(RGX3500 ONLY)
/
DC OUTPUT TERMINAL
OIL DRAINING PLUG (RGX3500 ONLY1
-16-
4-2 CONTROL PANEL
l
RGXI 800 : SOHz-11 OV, 6OHz-120V TYPE
DC
VOLTMETER
FUSE
CIRCUIT BREAKER
- AC RECEPTACLE
\
DC OUTPUT TERMINAL
‘EARTH (GROUND) TERMINAL
l
RGX2400 : SOHz-11 OV, 60Hz-120V TYPE
VOLTMETER
0
CIRCUIT BREAKER
+ AC RECEPTACLE
\
DC OUTPUT TERMINAL
EARTH (GROUND) TERMINAL
-17-
/