Robin America RGX180 User manual

-Rain G
Mot~ti’RG
RGX240,
issuE EMU -GS0068
q

CONTENTS
1. SPECIFICATIONS ..........................................
2. PERFORMANCE ...........................................
2-1 Model RGX180 ......................................
2-2 Model RGX240 ......................................
2-3 Model RGX240D .....................................
2-4 DC OUTPUT (RGX240, RGX240D) ........................
3. FEATURES ..............................................
4. GENERAL DESCRIPTION of GENERATOR ........................
4- 1 External View of Generator ..............................
4-2 RGX180 Panel .......................................
4-3 RGX240 Panel .......................................
4-4 RGX240D Panel. .....................................
5. CONSTRUCTION and FUNCTION ...............................
5- 1 Construction ........................................
5-2 Functions ..........................................
5-3 Description of Generator Operation .........................
5-4 Change of Engine Parts .................................
6. SAFETY PRECAUTIONS .....................................
7. RANGE of APPLICATIONS. ...................................
8. MEASURING PROCEDURE ...................................
9. CHECKING FUNCTIONAL MEMBERS. ...........................
9- 1 Stator Assembly ......................................
9- 2 Rotor Assembly ......................................
9- 3 Brushes. ...........................................
9-4 AVR (Automatic Voltage Regulator) ........................
9- 5 Fuse Holder and Circuit Breaker ...........................
9-6 Receptacle and AC Plug .................................
9- 7 Voltmeters and Pilot Lamp ...............................
9-8 Diode Stack Assembly ..................................
9-9 Primary Exciting Circuit ................................
10. DISASSEMBLY and REASSEMBLY ..............................
10- 1 Preparations and Suggestions .............................
10- 2 How to Disassemble ...................................
10- 3 How to Reassemble ....................................
10-4 Control Box Check, Disassembly, and Reassembly ...............
11. TROUBLE-SHOOTING .......................................
12.OPTIONS.. ..............................................
12-1 Caster .............................................
13. CIRCUIT DIAGRAM ........................................
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r----r ,
I
I I -I
RGX180 RGXZ40 I RGX240D I -
Self-Excltlry, 2 Pole, Single Phosc, Revolving-Fwlrl
6OHi!
50H7
15oow
13oow
1lOV 11.8A
22ov 5.9A
50Hz
2ooow
1700w
1lOV 15.5A
?2OV 7.7A
230V 7.4A
24OV 7.lA
24OOW
2ooow
11OV ( 18.21-1
50H7
Max. Output
Fuel
-
F WI Tank Caf,ac~ ly
Oil Capacity
Rt?vnltl Ilonlmln
Ignltlon SVSIWTl
Stwtlrlg SystRlrl
Fuel Consumption Ratio
1
Length
hrrrcnsiorts Width .-
Height
-_
)ry Weight
23OV b.7A
24OV 5.4A
18OOW
1500w
1lOV 13&A
12ov 12.5A
.-
12ov 16.7A
_-
.
2ooow
110 y/ 15.5A.i
/
/’ 22OV *, 7.7A
12OV/ ’ 14.2$, *’
/“24OV ,,./ 7.1 A
1.o
I .._.
Not avir~lablu 12V-8.3A IOOW
_-
AVR (Automatic Voltagv Hcgulijtor)
WIthin 3%
_.
Robin Atr-Cooled 4 Cyc!c, S~rtgltr Cylinder, Gasol~rw Engine
EYZOD (Wl-186)’
183cc~11.17cu.1n.)
4.7 Ps/3600 rpm, 4.0 Ps/3000 rpm
Automohllt! Gwolinc
10 lrters 12.6 LJ.S. gal.)
0.6 Ilters (1.3 U.S. plntsl
50H7.3000 rpm, 60H7-3600 rpm
Hohin Solid State Ignition System
Recoil Starter _.--.
1.l Iltcl /Hr (5OHrj 1.3 litc!r/Hr (60H7) 1.3 IItw/Hr (5OH.z) 1.5 liter/Hr (60H~) --.
552 mm (21.7 in.)
_. .__
377 mm 114.8 wt.)
_._ .--... . .
482 mm (19.0 in.)
. --
43 kg. (9.5 Ihs.1 I 44.5 kg. (98 Ihs.)
*For U. S. A. and Canadian markets

2. PERFORMANCE
2-1 MODEL RGX180
Type . _ . . . . . . . . . .
Power Factor . . . . . . . .
Engine . . . . . . . . . . .
. .
Self-Exciting. 2-Pole. Single Phase
. . 1.0
. . EY20D “(Wl-185)
t 62
z” 61
“3 60
f 59
,” 58
1
’ 120
LO
I I 1
3 6 9 1; 15
CURRENT (Al-
l
53 I I
1.5 3 4.5 6 7.5
CURRENT IA)-
1.5 3 45 6 75 9
CURRENT IA) -
I
- 1700
t 1
1500
5
-13005 E
-1100 2
r 900
I
- 1500 t
z
-1300 -
i f
1100 k
2
C
- 900
!
- 1500
t
- 1300 -
s
c
- 1100 2
3
T 900 c
1
Output Max. ............... 18OOW
Rated .............. 15OOW
Frequency. ................ 60Hz
Voltage. .................. 11OV
Output Max. ............... 15OOW
Rated .............. 13OOW
Frequency ................. 50Hz
Voltage. .................. 220V
Output Max. ............... 15OOW
Rated .............. 13OOW
Frequency. ................ 50Hz
Voltage. .................. 240V
NOTE: These characteristics are typical. Those of 6OH.z
120V and 5OHz 71OV or 230V are similar to
the above.
-2-

2-2 MODEL RGX240
Type ...............
Power Factor ..........
Engine ..............
Self-Exciting, 2-Pole, Single Phase
1.0
EY20D “(Wl-185)
I
4 6 ;I 10 12 14 16 18 20
-
CURRENT (A)
2 t
53
52
5 51
E 50
’
EI 49
u
u
- t
230
3 220
PJ 210
2 200
123456789
CURRENT7
250 / VC%TAGE
240-
230
220
‘23456789
CURRENT(A)
- 2000
Output Max. . . . . . . . . . . . . . . . 2400W
Iit
Rated . . . . . . . . . . . . . . 2000W
‘150 ( 3
Frequency. . . . . . . . . . . . . . . . . 60Hz
I 2 Voltage . . . . . . . . . . . . . . . . . . . 11 OV
‘1000
I
k
:
500
I
c
2000
Output Max. . . . . . . . . . . . . . . . 2000W
Rated .............. 17OOW
Frequency. ................ 50Hz
Voltage. .................. 220V
I
500
.. 2000
Output Max. ............... 2000W
f
Rated .............. 17OOW
-1 500 z
Frequency ................. 50Hz
c
I -3
Voltage . . . . . . . . . . . . . . . . . . .
1000
b
2
t
500
240V
NOTE: These characteristics are typical. Those of 6OHz
12OV and 5OHz 1IOV or 230V are similar to
the above.
-3-

2-3 MODEL RGX240D
Type ............... Self-Exciting, 2-Pole, Single Phase
Power Factor .......... 1.O
Engine .............. EY20D ‘(Wl-185)
61
60
59
250
240
230
I i I 1
0 2 4 6 8 10
CURRENT (A)-
0 2 4 6 8 10
CURRENT (Al -
1500 -
, I 3
5
b
.-1000 2
t
500
Output Max. . . .
Rated . .
. ~. . . . . .
Frequency. . . . .
Voltage . . . . . . .
........
........
. .
24OV-2400W
12ov- 1200w x 2
, . 24OV-2000W
12ov- 1ooow x 2
. . 60Hz
. . 12OV;24OV
Output Max. . . . . . . . . . . . . . . . 22OV-2000W
11ov-2oooW x 2
Rated _ . . . . . . . . . . . . . 22OV-1700W
11 OV-850W x 2
Frequency . . . . . . . . . . . . . . . . . 50Hz
Voltage . . . . . . . . . . . . . . . . . llOV:ll2OV
NOTE: These characteristics are typical. Those of 6OHz
1lOV/22OV and 5OHz 120!/1/24OV are similar
to the above.
-4-

2-4 DC OUTPUT (RGX240, RGX24OD)
DC Voltage ............................ 12V
DC Ampere ........................... 8.3A
DC Output .......................... 1OOW
CURRENT (A) -
If the generator is connected to a battery to charge it, its DC output voltage increases.The battery is charged at the increased
voltage level. Performance curve @ applies to a caseunder a resistanceload only; and curve @ representsbattery charging
characteristics.
NOTE: Up to the rated output it is possible to take out simultaneously the output of both AC and DC in total.
-5-

3. FEATURES
1. Lightweight, Compact
The Robin engine and revolving field generator designsprovide added output poxer per weight and economical opera-
tion.
7. Centralized Control
The witches. meters. and receptacles are located together on alarge-sizedcontrol box. and all operating controls are
located on top of the engine for eas)-generator operation.
3. Large IO-Liter GasTank
*IO-liter (2.6 LT.S.gal.) fuel tank is provided for nine hours of operation for Model RGSl8O and eight hours ior 1lodel
RGX240 (at the 5OHz rated output power,).
*The tank has a fuel gaugewhich shows the remaining amount of fuel m the tank.
4. Solid State Ignition System
*Unlike the breaker point svstem. the solid state rgnition s>-stemhas no contact points so that maintenance dur to
point wear is unnecessary-and constant output power can be maintained ior long periods.
*Increased spark eners makes starting cask-.
5. Extra-Quiet Operation
*X11models are equipped with alarge-sized.low-noise muifler.
*All models have a cl-clone type air cleaner of a low-noise, dustproof type.
6. Small Voltage Fluctuations by XVR (Automatic Voltage Regulator)
The automatic voltage regulator wtomatisally adjusts th2 exciting current to hold voltage regulation down to less
than 35. This helps prolong product life without dama-@ngthe electric devices.
7. DC Output for Battery Charging (RGX240. RGX240D)
The generaror can generate a DC output (13.. lOO\V)whtle generating an XC output so that batteries <anbe charged
during XC operation. In this case,make sure that the total XC and DC output doesnot exceed the rated output.
8. Dual Voltages are Available on RGX240D.
* -4 du-alvoltage type lvhich supplies AC voltage is available.
9. Output Voltage Waveform Close to Sine Wave
The output voltage a-aveform is close to a sine wave and is free of surgesso that the load w-ill not be damaged
10. Resistant to Inductive Load
Exiting poner is obtained tram the sub coil which is wound apart irom the main coil. This meanslessoutput roltage
fluctuations against load variation. and thus astead!-level ofpawer. This feature is efiective partrcularly for induction
motors. for example. kvhich are subject to sharp current variation.
11. 1005 Copper Windings
The windings are made onI>-of copper having lon internal resistance. This feature also helps improve generator effi-
mien+ and prolong generator lif2.
-6-

12. Easy Starting with Recoil Starter
13. Circuit Breaker for Troublefree Operation
14. Ruggedly Built Frame
The box type frame is so ruggedly built that two or more generators can be stacked. Another convenient feature of
the Robin generators.
15. A Caster Type is Optionally Available.
-7-

SPEED CONTROL LEVEH
CONTI301. BOX \ CHOKE KNOB STOP BUTTON
/ i I I
GENEHATOR FlJEl S~~-~AINEH AlI{ CLEANLIt MUFFLEt
FUEL GAUGE imd TANK CAP
FUEL TANK I SPARK PLUG
1
,
OIL GAUGE
,,.I,’
/ \
HUBBEH MOUNT I-iECOlL STARTEt7 tiANDLE
/
FlJEI COCK

4-2 RGX180 PANEL
4-2-l 1lOV, 120V
CIRCUIT BREAKER
AC RECEPTACLE 1 I
‘dc vi i “.
! ‘k.. I
/../- NEON LAMP
/ FUEL COCK
EARTH (GROUNDI TERMIN/AL FiJEL STRAINER
4-2-2 220V. 23OV, 240V
CIRCUIT BREAKER \
AC RECEPTACLE 1
EARTH fGROIJNDl TERMINAL FUEL STRAINER
/ NEON LAMP
/ FUEL COCK
_- 9 -

4-3 RGX240 PANEL
4-3-l 1lOV, 120v
CIRCUIT BREAKER ,,
AC RECEPTACLE 1 - .LOPEN, 1
, VOLTMETER
, DC FUSE 10A
DC OUTPUT
- TERMINAL
FUEL COCK
i
;/
/
/’ ;
EARTH !GROUNDI TERMINAL FUEL STRAINER
4-3-2 22OV. 23OV, 240V
CIRCUIT BREAKER
AC RECEPTACLE 1 \
/
,,‘.
,’
, VOLTMETER
/ DC FUSE 10A
- DC OUTPUT
TERMINAL
, FUEL COCK
EARTH (GROUND1 TERMINA; FUEL STRAINER
-10-

4-4 RGX240D PANEL
4-4-l llOV,‘22OV, 12OV,‘24OV
AC REC’IPTACLE 2
CIRCUIT BREAKER/
AC RECEPTACLE l-
-!
,
CIRCUIT
r-
BREAKER
I ON OFF
DC FUSE iOA
EARTH IGROUND) TERMINAL’
VOLTMETER
DC FUSE 10A
-DC OUTPUT
TERMINAL
FUEL COCK
\
FUEL STRAINER
-11-

STATOR COMPL. ROTOR COMPL.
I
;s
I
BRUSH HOLDER
THROUGH.BOLT SLIP RING COVER BOLT FRONT COVER SHAFT
-_ .- __
.--
RUBB’ER MOUNT RDTOd COMPL. ENGINE P.i.0. SHAFT
REAR COVER STATOR COMPL. COOLING FAN

5-2 FUNCTIONS
5-2-l STATOR
The stator consists of a laminated silicon steel sheet core,
copper wire which winds the core, and lead wires which de-
liver the power. The copper wire is wound into the main
coil. sub (.ausiliary) coil, and DC coil. XC output power
is taken from the main coil. and DC output power from
the DC coil. (DC coil is installed on Models RGX240 .md
RGXIOD only.) The outside diameters and laminated core
thickness of various models are asshow below.
Fig. 5 I
Fig. 5-2
MODEL RGXISO RGX240
RGX240D I
60 70
2.36 2.76
I
Table 5 1
- 13 -

5-2-2 ROTOR
The rotor consists of a laminated silicon steel sheet cover
with a iield coil wound arcund it and cooling fans and slip
rings at both ends of the shaft. The field coil leads are con-
nected to the slip rings and direct current (DC) to the field
coil turns the rotor and magnet. The cooling fans cool the
generator by drawing cooling air from the slip rings and dis-
charging it through the fans.
FAN
SLIP RING
BEARING ’
Fig. 5-3
I’
c----l----
II-
Fig. 5-4
MODEL / RGX180 RGX240
RGX240D
d (mm) i 99.6 99.6
(In.) , 3.92 3.92
I (mm) 60 70
(in.i 2.36 2.76
Table 5- 2
-14-

An exciting current is supplied from the AVR to the rotor.
The brushes are made of carbon, and the brush-holders of
plastic. It is necessaryto keep the contact pressurebetween
the brushes and slip rings within specitic limits. Thus. care
must be taken about brush length. (See 9-3 BRUSHES.)
Fig. 5-5
5-2-3 BRUSHES
5-2-4 AVR (AUTOMATIC VOLTAGE REGULATOR)
The automatic voltage regulator employs an electronic cir-
cuit to automatically regulate voltage.
L
Fig. 5-6
5-2-5 VOLTMETER and PILOT LAMP
Models RGX340 and RGX21OD hav-e a voltmeter that __
comes in t\vo t>-pes: 15OV maximum tppe and 3OOVmaxi-
mum type. The tl-pe of voltmeter indicates generator out-
put voltages. The generators with a generated voltage of
11OV or 13OV and dual voltage type use the 15OV msimum ’
t!-pe voltmeter: and those of 22OV. 23OV and 24OV specifi-
~-::,i;--
cations use the 3OOVmaximum type voltmeter. 1
300V MAX. 15OV MAX.
Model RGXISO employs a pilot lamp. The lamp hghts :
i22OV. 23OV. 24OV) (llOV, 12OV)
when a voltage is generated. The pilot lamp also comes in
Fig. 5-7 (1)
two types: 12% t>-pe and 3OV type. These t>-pesare
selected to suit generator output voltage.
1
J
Fig. 5- 7 (11)
- 15-

5-2-6 CIRCUIT BREAKERS
Models RGX180 and RGX240 have a pushbutton circuit
breaker and Model RGX240D two pushbutton circuit 1
breakers. Nomrallp, the pushbutton circuit breaker is closed
with the button pushed into the panel to keep the circuit :
live. If an overcurrent runs. the button comes out to break
the circuit. The circuit can be closed againby simply push-
ing the button in. The circuit breaker is a thermo-sensitive i
type so. if the temperature inside the circuit breaker is still
high immediately after the circuit has opened, the button
may not be able to be pushed in to the ON position. or ma>- 1
come back out again at once. In that case,wait awhile until
the inside temperature falls. and then push the button in.
Fig. 5-8
Circuit breaker capacities are asfollows:
1
Model Specification Circuit Breaker ’ Quantity
Capacity per Unit
RGX180 11ov. 120v
15A ’ 1
RGX180 , 22OV, 23OV. 240V 8A 1
I
RGX240 1lOV, 120v 20A
1
RGX240 220V. 230V. 240V 10A 1
RGX240D 11Ol22OV. 12Ol24OV 10A
2
Table 5-3
- 16 -

5-2-7 FUSE
The fuse prevents DC output overcurrent and short<ircuir overcurrent. Ii the generator is operated at alevel exceeding the
maximum current. it can causeinsulation deterioration. ‘curninp. electric shock. and electric leakage.The fuse protects the
generator from these troubles. Fusecapxiry: 10.1
5-2-8 RECEPTACLE and AC PLUGS
These are used for raking XC output power from the generator. A total of rhree kinds of receptacles,eachvar)-ing in rated
voltage and current from another, are used. As man; XC plugs as the receptacles. each matching the corresponding recep-
tacle. are provided. Table 5-4 shows the rated current for each receptacle. Be careful not to use the receptacles and XC
plugs beyond the specified limits to prevent burning.
Fig. 5-4
5-2-9 TERMINALS
The terminals are for producing DC output power. and
come in two colors. red and black. The red one is $ositive
I+1.and the black one negative I - )
5-2-10 FRONT COVER
Ths front cover 1sdn alummum die CastmEand is mow-ted
on the mam besrmg cover ai the ensns. It has\~entsto dls-
charge ;oolmg dir from the generator anil the vents are Le-
signed to pwent fingers from entering.
I
RED BLACK
1
Fig. 5- 10
1
I
I
Fig. 5- I 1
- 17 -

5-2-11 REAR COVER
The rear cover is also an alumrnum die casting. and has a
faucet joint to hold the stator together w-ith the front cover.
It has bosses inside for holding the brushes, and slits for
taking cooling air in. The slits are so designed that htrman
fmgers will not go in.
5-2-12 RUBBER MOUNTS (RUBBER VIBRATION
ISOLATORS)
Rubber pads for controlling generator vibration and disloca-
tion. These are made of the most suitable rubber material
to optimum shapeand hardness.
Models RGX180. RGX240. and RGXI4OD in particular
usediagonal support rubbers to reduce vibration.
5-2-13 PIPE FRAME
Fig. 5- 12
I
1 I
Fig. 5- 73
The pipe frame consists of a pipe frame skeleton. side plates X and B and box stak-.
SIDE PLATE B