Robin America RGX7100 User manual

SERVICE

MANUAL

RGX7100, 7800

GENERATORS

Models

PUB-GS6828

Rev. 07/09

Robin America, Inc.

905 Telser Road • Lake Zurich, IL 60047 • Phone: 847-540-7300• Fax: 847-438-5012

e-mail: [email protected] • www.subarupower.com



Section Title Page

                                                           

                                                    

                                                    

                                                  

                                                 

5-1 MEASURING INSTRUMENTS                                              12

5-2 AC OUTPUT MEASURING                                                 14

5-3 DC OUTPUT MEASURING                                                14

5-4 MEASURING INSULATION RESISTANCE                                    14

                                          

6-1 RECEPTACLES                                                         16

6-2 CIRCUIT BREAKER                                                      17

6-3 STATOR                                                               18

6-4 ROTOR ASSEMBLY                                                      19

6-5 BRUSH                                                                20

6-6 AVR (AUTOMATIC VOLTAGE REGULATOR)                                20

6-7 DIODE STACK                                                          22

6-8 OIL SENSOR                                                           23

6-9

IDLE CONTROL (OPTIONAL EQUIPMENT)                                        24

                                              

7-1 PREPARATION and PRECAUTIONS                                        27

7-2 DISASSEMBLY PROCEDURES                                            27

7-3 COMPONENT PARTS                                                    33

7-4 ASSEMBLY PROCEDURES                                               37

7-5 CHECKING, DISASSEMBLY and REASSEMBLY of the CONTROL PANEL          48

                                                       

8-1 NO AC OUTPUT                                                         49

8-2 AC VOLTAGE IS TOO HIGH OR TOO LOW                                   50

8-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED   51

8-4 NO DC OUTPUT                                                         52

                                                          

NOTE

ThisServiceManualexcludesinformationforengine.

Asforthetotalservicinginformationasageneratorset,pleasereferinconjunctionwiththe

RobinEX35/40OHCEngineServiceManual.

- 1 -

 

  



Type Brush, self-exciting, 2-poles, single phase

Voltage regulating system AVR type

AC Output

Rated voltage V 50Hz 220, 240

60Hz 120 / 240

Rated current A 50Hz 209, 192 25, 229

60Hz 417 / 208 50 / 25

Rated output VA (W) 50Hz 4600 5500

60Hz 5000 6000

Rated power factor 10

Safety device type Fuse-less circuit breaker

DC Output

Rated voltage V 12

Rated current A 83

Safety device type Fuse-less circuit breaker



Model EX35D EX40D

Type ROBIN, Air-cooled, 4-stroke, OHC, Gasoline Engine

Displacement mL 404

Fuel Automotive Unleaded Gasoline

Fuel tank capacity L

220

(275)*1

Engine oil capacity L 12

Spark plug BR-6HS (NGK)

Starting system Electric starter / Recoil

Direction of rotation Counter - clockwise



Length mm 725 (975)*2

Width mm 530

Height mm 580

Dry weight kg 86(96)*3 88(98 )*3



*1: ( ) shows the filled amount up to the "LEVEL" position

*2: ( ) shows dimensions with Battery frame

*3: ( ) shows dry weight with Electric starter

- 2 -





50Hz-220V

50Hz-240V

N / A

- 3 -

4000

5000

6000

7000

8000

62.5

60

57.5

55

0

1000

2000

3000

[115]

[120]

[125]

230

250

240

Voltage (V) Frequency (Hz)

Output (VA)

Current (A)

Voltage (V)

Frequency (Hz)

Output (VA)

0 10 20 30 40 50 60 70

60Hz-120/240V

- 4 -



50Hz-220V

50Hz-240V

N / A

- 5 -

4000

5000

6000

7000

8000

9000

57.5

0

1000

2000

3000

230

[115]

62.5

65

60

55

250

[125]

240

[120]

Voltage (V) Frequency (Hz)

Output (VA)

Current (A)

Voltage (V)

Frequency (Hz)

Output (VA)

0 10 20 30 40 50 60 70

60Hz-120/240V

- 6 -





Control panel

Fuel tank

Fuel gauge

Engine switch

Recoil starter

handle

Choke lever

Oil gauge (oil filler)

Spark plug cap

Air cleaner

Muffler

Tank cap

Recoil starter

Muffler cover

Oil drain plug

Fuel strainer

(Fuel valve)

- 7 -



V

(50Hz-220V, 240V)

(60Hz-120/240V)

Voltmeter

DC circuit

breaker

AC circuit

breaker

Earth

(

ground

)

terminal

AC

receptacle

DC receptacle

Engine switch

[Electric starter model]

Key switch

AC circuit

breaker

DC circuit

breaker

AC receptacle 20A

Engine switch

[Electric starter model]

Key switch

AC receptacle 30A

Pilot lamp

Full power

switch

AC receptacle 30A

Earth

(

ground

)

terminal

Hour meter

DC

receptacle

Idle Control Switch

- 8 -

PROD No. / SER No.

(

Label

)



Serial number is stamped on the label stuck on the control box

NOTE:Alwaysspecifyserialnumberwheninquiringaboutthegeneratorororderingspareparts

inordertogetcorrectpartsandaccurateservice.



AVR UNIT

EARTH TERMINAL

BRUTH

STATOR CORE

ROTOR BOLT

END COVER

REAR COVER

FRONT COVER

FLANGE BOLT

BRUSH HOLDER

N-BRACKET

STATOR BOLT

DIODE STACK



- 9 -



Generally, the power rating of an electrical appliance indicates the amount of work that can be

done by it The electric power required for operating an electrical appliance is not always equal to

the output wattage of the appliance The electrical appliances generally have a label showing their

rated voltage, frequency, and power consumption (input wattage) The power consumption of an

electrical appliance is the power necessary for using it When using a generator for operating an

electrical appliance, the power factor and starting wattage must be taken into consideration

In order to determine the right size generator, it is necessary to add the total wattage of all

appliances to be connected to the unit

Refer to the followings to calculate the power consumption of each appliance or equipment by its

type



Total power consumption must be equal to or less than the rated output of the generator

 A rated 3000W generator can turn thirty 100W incandescent lamps on





Select a generator with a rated output equivalent to 12 to 2 times of the power consumption of

the load Generally the starting wattage of motor driven tools and light electrical appliances are

12 to 3 times lager than their running wattage

 rated 250 W electric drill requires a 400 W generator to start it

NOTE1:Ifapowerfactorcorrectioncapacitorisnotappliedtothefluorescentlamp,themore

powershallberequiredtodrivethelamps.

NOTE2:

Nominalwattageofthefluorscentlampgenerallyindicatestheoutputwattageofthelamp.



Therefore,ifthefluorescentlamphasnospecialindicationastothepowerconsumption,

efficiencyshouldbetakenintoaccountasexplainedinltem(5)onthefollowingpage.



Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up

 A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on A

rated 3000 W generator can power two or three 400 W mercury lamps



These appliances require large starting wattage which is 3 to 5 times of running wattage

 A rated 900 W compressor requires a 4500 W generator to drive it

NOTE1:Motor-drivenappliancesrequiretheaforementionedgeneratoroutputonlyatthe

starting.Oncetheirmotorsarestarted,theappliancesconsumeabout1.2to2times

theirratedpowerconsumptionsothattheexcesspowergeneratedbythegenerator

canbeusedforotherelectricalappliances.

NOTE2:Motor-drivenappliancesmentionedinitems(3)and(4)varyintheirrequiredmotor

startingpowerdependingonthekindofmotorandstart-upload.Ifitisdifficultto

determinetheoptimumgeneratorcapacity,

selectageneratorwithalargercapacity.



- 10 -

Efficiencies of some electrical appliances are as follows :

Single-phase motor     06 to 075

Fluorescent lamp       07 to 08

 A 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 07

and accordingly, power consumption will be 40÷07= 57W As explained in Item (2),

multiply this power consumption value of 57 W by 12 to 2 and you will get the figure

of the necessary capacity of a generator In other words, a generator with a rated

output of 1000W capacity can light nine to fourteen 40 W fluorescent lamps

 Generally speaking, a 400 W motor means that its work load is 400 W Efficiency of

this motor is 07 and power consumption will be 400÷07= 570 W When this motor is

used for a motor-driven tool, the capacity of the generator should be multiple of 570

W by 12 to 3 as explained in the ltem (3) 570 (W) × 12 to 3 = 684 (W) to 1710 (W)



Some appliances have no indication as to power consumption; but instead the work load

(output) is indicated In such a case, power consumption is to be worked out according to the

numerical formula mentioned below

(Output of electrical appliance)

(Efficiency)

= (Power consumption)

The smaller the motor, the

lower the efficiency

( )

Table.4-1





 

   

    



   

    

    

- 11 -

NOTES:Wiringbetweengeneratorandelectricalappliances

1. Allowablecurrentofcable

Useacablewithanallowablecurrentthatishigherthantheratedinputcurrentoftheload

(electricalappliance).Iftheinputcurrentishigherthantheallowablecurrentofthecable

used,thecablewillbecomeexcessivelyheatedanddeterioratetheinsulation,possibly

burningitout.Table4-2showscablesandtheirallowablecurrentsforyourreference.

2.Cablelength

Ifalongcableisused,avoltagedropoccursduetotheincreasedresistanceinthe

conductorsdecreasingtheinputvoltagetotheload(electricalproduct).Asaresult,theload

canbedamaged.Table4-2showsvoltagedropsper100metersofcable.

Voltage drop indicates as

R means resistance (Ω/100 m) on the above table

I means electric current through the wire (A)

L means the length of the wire (m)

The length of wire indicates round length, it means twice the length from generator to

electrical tools

Table.4-2

















 

mm

2

No A No/mm Ω/100m 1A 3A 5A 8A 10A 12A 15A

075 18 7 30/018 2477 25V 75V 125V

- - - -



125 16 12 50/016 1486 15V 45V 75V 12V 15V 18V

-

20 14 17 37/026 0952 1V 3V 5V 8V 10V 12V 15V

35 12 to 10 23 45/032 0517

-

15V 25V 4V 5V 65V 75V

55 10 to 8 35 70/032 0332

-

1V 2V 25V 35V 4V 5V

1

V=

100

× R × I × L

- 12 -

 

FORAC

(2) AMMETER

AC ammeter is necessary

An AC ammeter with a range that can be

changed according to the current rating of

a given generator is most desirable

(About 10 A, 20 A, 100 A)

(3) FREQUENCY METER

Frequency range : About 45 to 65Hz

NOTE:Becarefulofthefrequencymeter's

inputvoltagerange.

FORAC



(1) VOLTMETER

AC voltmeter is necessary

The approximate AC voltage ranges of the

voltmeters to be used for various types of

generators are as follows :

0 to 150 V : Type with an output voltage of

110 or 120 V

0 to 300 V : Type with an output voltage of

220, 230 or 240 V

0 to 150 V, 0 to 330 V : Dual voltage type

- 13 -

(4) CIRCUIT TESTER

Used for measuring resistance, etc

(5) MEGGER TESTER

Used for measuring generator insulation

resistance

Select one with testing voltage range of

500V

(6) TACHOMETER

Use the contactless type tacho meter

- 14 -



Use a megger tester to check the insulation

resistance Remove the control panel, and

disconnect the connector of GREEN lead for

ground Connect a megger tester to one of

receptacle output terminals and the ground

terminal, then measure the insulation resistance

MEGGER TESTER



SWITCH

LOAD

TO AC RECEPTACLE

F

A

~

V

~



Use a circuit above for measuring AC output

A hot plate or lamp with a power factor of 10

may be used as a load Adjust the load and rpm

and check that the voltage range is as specified

in the following table at the rated amperage and

rated rpm

Measurement of DC output is executed with the

switch turned ON while the current is regulated

at 83A by adjusting the load to the generator

If the voltage is within the range from 10V, the

voltage output is normal

NOTE:Ifabatteryisconnectedasaloadtothegenerator,theDCoutputvoltagewillincrease

byapproximately1to2V.Therefore,carefullyobservetheelectrolytelevelanddonot

overchargethebattery.

 



  

RGX7100

50

-

219 - 228 239 - 248



60

118 - 127 219 - 228 239 - 248

RGX7800

50

-

219 - 228 239 - 248

60

118 - 127 219 - 228 239 - 248

- 15 -



Measure the insulation resistance between

the slip ring and the core



Measure the insulation resistance between

the live parts and the grounded parts

Any part where the insulation resistance is less than 1MΩ has faulty insulation, and may cause

electric leakage and electric shock

Replace the faulty part

MEGGER TESTER

SLIP RING

ROTOR

MEGGER TESTER



Measure the insulation resistance between

each lead wire and the core

MEGGER TESTER

An insulation resistance of 1 megohm or more is normal

(The original insulation resistance at the time of shipment from the factory is 10 megohm or more)

If it is less than 1 megohm, disassemble the generator and measure the insulation resistance of

the stator, rotor and control panel individually

- 16 -

 



Using a circuit tester, check continuity between

the two terminals at the rear of the receptacles

while the receptacle is mounted on the control

panel

When continuity is found between the output

terminals of the receptacle with a wire connected

across these terminals, the receptacle is normal

When the wire is removed and no continuity is

found between these terminals, the receptacles

are also normal

CIRCUIT TESTER

(Continuity test)

CIRCUIT TESTER

(Continuity test)

WIRE

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