Robin RGD2500 User manual

SERVICE
MAIUUAL -
--
Model
RGD2500,RGD3300
Generator
PUB-GS1186
Rev. 8198

CONTENTS
.
Section Tile Page
1 . SPEClFlCATlONS ....................................................................................................... 1
2 . PERFOMANCE CURVES ........................................................................................... 2
2-1 MODELRGD2500 ................................................................................................. 2
2-2 MODELRGD3300 ................................................................................................. 2
2-3 DC OUTPUT ......................................................................................................... 2
3 . FEATURES .................................................................................................................. 3
4 . GENERAL DESCRIPTION .......................................................................................... 4
4-1 EXTERNALVIEW ................................................................................................. 4
4-2 CONTROLPANEL ................................................................................................ 5
4-3 LOCATION of SERIALNUMBER and SPECIFICATION NUMBER ...................... 6
5 . CONSTRUCTION AND FUNCTION ........................................................................... 7
5-1 CONSTRUCTION ................................................................................................. 7
5-2 FUNCTION ............................................................................................................ 7
5-3 GENERATOR OPERATION ................................................................................ 11
6 . SAFETY PRECAUTIONS ......................................................................................... 14
7 . RANGE OF APPLICATIONS .................................................................................... 15
8 . MEASURING PROCEDURES .................................................................................. 18
8-1 MEASURINGINSTRUMENTS ........................................................................... 18
8-2AC OUTPUTMEASURING
................................................................................. 21
8-3 DC OUTPUT MEASURING ................................................................................. 21
8-4 MEASURING INSULATIONRESISTANCE ........................................................ 22
9 . CHECKING FUNCTIONAL MEMBERS .................................................................... 24
9-1VOLTMETER ....................................................................................................... 24
9-2AC RECEPTACLES
............................................................................................ 24
9-3 NO-FUSEBREAKER
........................................................................................... 24
9-4STATOR
.............................................................................................................. 25
9-5 ROTOR ASSEMBLY ........................................................................................... 26
9-6 CONDENSER ..................................................................................................... 26
9-7 DIODE RECTIFIER
............................................................................................. 27
10 . DISASSEMBLY AND ASSEMBLY .......................................................................... 29
10-1 PREPARATION and PRECAUTIONS ............................................................... 29

Section Title Page
10-2 SPECIAL TOOLS for DISASSEMBLY and ASSEMBLY .................................... 29
10-3 DISASSEMBLYPROCEDURES ....................................................................... 30
10-4 ASSEMBLY PROCEDURES ............................................................................. 38
10-5 CHECKING. DISASSEMBLY and REASSEMBLY of the CONTROL BOX ....... 51
t 1 . TROUBLESHOOTING ............................................................................................ 53
11-1 NO ACOUTPUT ................................................................................................ 53
11-2 AC VOLTAGE IS TOO THIGH OR TOO LOW ................................................... 54
11-3 AC VOLTAGE IS NORMAL AT NO.LOAD. BUTTHE LOAD CANNOT BE APPLIED ..... 55
11 -4 NO DC OUTPUT ............................................................................................... 56
11 -5 OILSENSOR TROUBLESHOOTING ....................... ....................................... 57
12 . WIRING DIAGRAM ................................................................................................. 58

r I
U
0
z
W
s
a
5
a
I
-
Model
RGD2500
RGD3300
I
Brushless, Self Exciting, 2-Pole, Single Phase
I
I
Frequency 60
Hz
60 Hz
I
Maximum Output
Rated Output
AC
3300 W 2500 W
3000
W
2200 W
Rated
Current
25.0N 12.5A 120Vl240V 18.3N 9.2A 120V/240V
120
v
25.0 A 120 v
18.3 A
Voltage
Power Factor
1 .o
DC Output
Voltage Regulator
12V-8.3
A (1 00 W)
Condenser Type
Type Air-Cooled CCycle, Diesel Engine
Model DY23-2D
I
i
i
DY27-2D
~
Displacement I 230 cm3(14.04cu.in.) I 265 cm3(16.17cu.in.) I
Rated Output 4.8 HP / 3600 rpm
2.06
U.S. gal. (7.8 liters)
Fuel Tank Capacity
Diesel light oil Fuel
5.5 HP / 3600 rpm
I
~ ~~ ~~~ ~
Rated Coutinuous Operation I 1.10 hours I 1.30hours
Oil Capacity
Recoil Starter and Optional Electric Starter
Starting System
0.9 liters
I Dimensions (L x W x H) 21.1
~15.8~18.0in(27.9~15.8~18.0in)’/536~400~458
mm (709 x 400 x.458 mm)*
I Dry Weight
!
I 55 kg(58.5kg.)’ / 121 Ibs.
58.5 kg (62 kg.)’ / 128.7 Ibs.
I (129 Ibs.)’
(1 37 I&.)*
Electric starter motor is available as option.
- 1-

2. PERFOMANCE CURVES
2-1 MODEL RGD2500
-
2k
t
A
s
a
n
I-
O
3
-
lk
-0
CURRENT(A) -
2-2 MODEL RGD3300
CURRENT (A) +
2-3 DC OUTPUT
16
14
v
5 12
g 10
0246810
CURRENT(A) "+
3k
2k
t
3
CI
Y
Output Max. ................. 2500 W
Output Rated ............... 2300 W
Frequency .................... 60 Hz
Voltage ......................... 120 V
Output
Max. ..............
3300 W
Output Rated ............
3000 W
Frequency .................
60 Hz
Voltage
120 V/240V
e
......................
0
DC Voltage .................. 12 V
DC Ampere ................. 8.3 A
DC output .................... 100 W
The voltage curve shown in the left indicates the char-
acteristic
of DC output when charging a battery.The
voltage may be decreased
by 20% when the resis-
tance load
is applied.
NOTE : It is possible to use both DC and AC outputs
simultaneously up
to the rated output in total.
- 2-

3-1 BRUSHLESSALTERNATOR
Newly developed brushless alternator eliminates troublesome brush maintenance.
3-2 EASYSTARTING
Light pull recoil starter accompanied with automatic decompression system makes the new RGD series
generators even easierin starting than gasoline engine generators.
3-3 QUIET OPERATION
The new KGD series generator provides quiet operation by means of:
The superb design of intake-exhausr system.
Direct injection combustion system.
A large super silent muffler.
An efficient low noise air cleaner.
3-4 ECONOMICALPERFORMANCE
On top of well known diesel economy. the air-coolea Robin diesel engine features direct fuel injection
and special designrefinemem for extra fuel efficiency.
3-5 OIL SENSOR
The OIL SENSOR automatically shuts the engine off whenever the oillevel falls down below a safelevel
preventing engine seizure.
3-6 COMPACT, LIGHT WEIGHT
Thecombinationof newiydevelopedbrushless alternatorandair-cooledsinglecylinderRobindiesel
engine enables the new
RGD series generatorsto be very compact in size and lightin weight.
3-7 RELIABLEPERFORMANCEWITH MINIMAL MAINTENANCE
A brushless alternator eliminates troublesome brush maintenance.
A drip-proof alternator design.
A trouble free condenser voltage regulator.
A fuselesscircuitbreaker.
A dust-proof dual element air cleaner.
The OIL SESSOR automatically shuts the engine off whenever the oil level falls down below a safe
level preventing engine seizure.
3-8 LONG-LIFEDURABILITY
C'onlpact and smooth running air-cooledRobindieselenginelastsmuchlongerthanthegasoline
engine
of the same size.
Trouble-freebrushlessalternatorwithcondensertypevoltageregulatorworksalltheyearround
without any maintenace work.
- 3-

4.GENERAL DESCRIPTION
4-1
EXTERNAL VIEW
No-fuse bmakei
Speed controlleverRockercover
Fullmwerswitch
I- / /
Air cleaner
(DU~ voltage type o
Key switch
(Only for RGD3300)
\
/
Fuel injection pump
\
DC output terminal
Stop lever
.
Earth terminal Fuelfi&rOil
filter Fuelcock
/
Muffler
Electric starter
(only for
RGDSOO)
/
\
Oil gauge
- 4-

4-2 CONTROL PANEL
_-
RGD2500, RGD3300 : 60HZ-l20V, 60H~-120V/240V TYPE
Full power switch
Key switch
(Only
for RGD3300)
Vottmeter
i, I((
DC output terminal
7
DC fuse
@ 1111
/ No-fuse breaker
/Ac receptacle
/ Earth terminal
- 5-

4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER
Serial number and specification number are stamped on the LABEL (MODEL NAME) stuck on the side
wall of control box. w
NOTE : Always specify these numbers when inquiring about the generator or orderingspare parfs in
order to get correct
parts and accurate service.
Specifications label
- 6-

5.CONSTRUCTION AND FUNCTION
GeneratorbaseMountrubber BallbearingThrough
bolt Support ring Frontcover
Fig- 5-7
5-2 FUNCTION
5-2-1 STATOR
The stator consists of a laminated silicon steel
sheet
core, a main coil and acondenser coil which
are woundinthe core
slots.
The condenser coil excites the rotor field coil which
generates
AC voltage inthe main coil.
Fig. 5-2
- 7-

5-2-2 CONDENSER
One or two condensers are installed in the con-
trol box and are connected to the condenser coil
of the stator.
These condensers and condenser coil regulate
the
output voltage.
5-24 ROTOR
The rotor consists of a laminated silicon steel sheet
core andafield coil which
is wound over the core.
DC current in the field coil magnetizes the steel
sheet core.Two permanent magnetsare provided
for the primary exciting action.
A diode rectifier and surge absorber is mounted
inside of the insulator.
I
Fig. 53
Fig. 5-4
Diode rectifier and Surge absorber
Fig. 5-5
- a-

5-2-4 DC FUSE
(1) The 10 ampere DC fuse mountedon the con-
trol panel protects whole DC circuit from get-
ting damage by overload or short circuit.
(2) The 15 ampere DC fuse in the control box pro-
tects the diode rectifier from getting damage
by reverse connectionto thebattery.
(Electric
start model)
I
Fig. 5-6
5-2-5 NO-FUSE BREAKER
The no-fuse breaker protects the generator from getting damage by overloading or short circuit in the
appliance.Table
5-1 shows thecapacrty of no-fuse breaker by each spec. and their object of protection.
MODEL OBJECT
or PROTECTION NO-FUSE BREAKER SPECIFICATION
60 HZ-120 V
RGD2500 20
A
10Ax2
60 HZ-1 20 V, 240V
Total output amperage
Total
output amperage
RGD3300 60 HZ-120
V
Total output amperage
14Ax2 60 HZ-1 20 V, 240V
Total output amperage
27 A
Table. 5-1
1
Fig. 5-7
- 9-

5-2-6 RECEPTACLE and AC PLUG (STD.SPEC.)
These are used for taking AC output power from the generator. A total of six kinds of receptacles, each
varying inrated voltage and current from another, are used. Each model has at least one receptacle to
deliver the rated generator output.
As many AC plugs as the receptacles, each matching the correspond-
ing receptacle, are provided. Table
5-2 shows the rated current for each receptacle. Be careful not to use
the receptacles and AC plugs beyond the specified amperage limitsto prevent burning.
w
NOTE 7 : If your generator has receptacles pecu-
liar
to your county, Table 5-2 does not
apply.
NOTE
2 :The generator for U.S.A. market is
equipped withNEMA standard recep-
tacles shown
in table 5-2.
Use the proper plug for connecting ap-
pliance to the generator.
Caution : To connect the appliance to locking
receptacle, insert
the plug intothe re-
ceptacle and turn it clockwise to lock.
Fig. 5-8
Style
Description
AC plug
Receptacle
Ampere
~1
20A
GFCl
125V
(Ground Fault
NEMA NEMA
5-20R
Circuit interrupter)
5-20P
Receptacle, duplex
@
125VI250V NEMA NEMA
20A
L14-2OP L14-20R
Locking Receptacle
1 25V
L5-30P
L5-30
30A NEMA
NEMA
Locking Receptacle
Table. 5-2
- 10-

5-3 GENERATOR OPERATION
PERMANENT MAGNET
FOR INITIAL EXCITATION
FIELD COIL \
STATOR
r--- 1
MAIN COIL
I
"""1
I
"""""I
Fig. 5-9
5-3-1 GENERATION Of NO-LOAD VOLTAGE
(1) When the generator starts running, the permanent magnet built-intothe rotor generates 3 to 6V of AC
voltage inthe main coil and condenser coil wound on the stator.
(2) As one or two condensers are connected to the condensercoil, the small voltage at the condenser
coilgenerates a minute current
8) which flows through the condenser coil. At this time, a small fluxis
produced with which the magnetic force at the rotor's magnetic pole is intensified.When this mag-
netic forceis intensified, the respective voltages in the main coil and condenser coil rise up.
As the
current
3 increases, the magnetic flux at the rotor's magnetic pole increases further. Thus the volt-
ages at the main coil and condenser coil keep rising
by repeating this process.
(3) As AC current flows through the condenser coil, the density of magnetic fluxinthe rotor changes. This
change of magnetic flux induces
AC voltage in the field coil, and the diode rectifierinthe field coil
circuit rectifies this
AC voltage into DC. Thus a DC current 13 flows through the field coil and magne-
tizes the rotor core to generate an output voltage in the main coil.
(4) When generator speed reaches 3000 to 3300 rpm, the currentinthe condenser coil and field coil
increases rapidly. This acts to stabilize the output voltage
of each coils. If generator speed further
increasestothe rated value, the generator output voltage
will reach to the rated value.
5-3-2 VOLTAGE FLUCTUATIONS UNDER LOAD
When the output current @ flows through the main coil to the appliance, a magnetic fluxisproduced and
serves to increase current
@ in the condenser coil. When current @ increases, the density of magnetic
flux across
the rotor core rises. As a result, the current flowing in the field coil increases and the genera-
tor output voltage is prevented from decreasing.
- 11 -

5-3-3 FULL POWER SWITCH (Dual Voltage Type)
The full power switch is provided forthe dual voltage typetotake out the full rated power from one
receptacle ineach voltage.
1"
REc21&
$"" /
-
-
I
, IREC1
Fig. 5- 11
-1
1 OV)
1 1 RECEPTACLE I RECEPTACLE
LOWER VOLTAGE HIGHER VOLTAGE
110 v
I ,orv I Rated output
I
No output can be
taken.
I
110/220 v
120/240 V
or
Tale. 5-4
Rated output
Half
of rated output
Fig. 5-12
- 12-

Two main coils are wound over stator core. Each main coil outputs half the rated power at the lower
voltage
(11OV or 12OV). These main coils are wound to beinthe same phase. Thefull power switch
reconnects these main coils
in parallel or in series.
Fig.
5-1 0 shows a circuit diagram. Whenthe fullpower switchisset for single lower voltage indication
(11OV or 12OV), the switch positionisas indicated by the lower solid line in the diagram.Fig. 5-11 is a
simplified representation of this circuit, showing the two main coils connected in parallel.ln this case, the
higher voltage
(22OV or 240v) at Rec. 3 cannot be taken out. Rec. 2 for the lower voltage can output up
to the rated power (up to
30A if the rated current is over 30A), and Rec. 1 can output up to a totalof 15A.
When the fullpower switchisset for double voltage indication (11OV/22OV or 120V/240V), the switch
positionisas indicated by the upper dotted line in Fig.
5-10. Fig. 5-12 is a simplified representation of this
circuit, showing the
two main coils connectedinseries. In thiscase, power can be taken simultaneously
fromthereceptacles for the both voltages. Rec.
3 for the higher voltage can output uptothe rated power,
but Rec.
1 and Rec. 2 for the lower voltage can output only up to half the rated power each.
Table
5-4 is a summary of the above explanation. Select the proper output voltage by full power switch in
accordance withtheappliance to beused.
"
- 13-

6.: SAFETY PRECAUTIONS
1. Useextreme caution near fuel. A constantdanger of explosion or fireexists.
Do not fill the fuel tank whilethe engineis running. Do not smoke or use opem flame nearthe fuel
tank. Be careful not to spill fuel when refueling.
If spilt, wipeitand let dry before starting the engine.
2. Do not place inflammablematerialsnear the generator.
Be careful notto put fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near the
generator.
3. Do notoperatethe generator inaroom,cave ortunnel. Always operatein a well-ventilatedarea.
Otherwise the engine may overheat and also, the poisonous carbon monoxide contained in the ex-
haust gases will endanger human lives. Keep the generator at least
1 m (4 feet) away from structures
or facilities duringuse.
4.Operate the generator ona levelsurface.
5.
6.
If the generator is tilted or moved during use, thereisa danger of fuel spillage and a chance that the
generator may tip over.
Do notoperatewith wet handsor in the rain.
Severe electric shock may occur.
If the generatoriswet by rain or snow, wipe it and thoroughly dry it
before starting.
Don't pour water overthegenerator directly nor washitwith water. If the generatoris
wet with water, the insulations
will be adversely affected and may cause current leakage and electric
shock.
Do notconnectthe generatortothecommercial power lines. w
This may cause a short-circuit or damagetothe generator. Use a transfer switch (Optional parts) for
connecting with indoor wiring.
NOTE : Theparts numbers of the transfer swifches and of the plastic box to store themareas shown in
Table
6- 1.
Part No. PartName Q'ty Phase Allowable Current
Table. 6-1
365-45604-08 Transfer Switch
11 15
A
367-45605-08 Transfer Switch
11 30
A
340-45606-08
Transfer Switch 1 1 60 A
367-43008-08 Plastic Box
11 30 A
348-43009-08 Plastic Box 1160 A
Table. 6-1
7. Be sureto check andremedy thecauseof circuitbreaker tripping before resetting it on.
CAUTION : If the circuitbreakertripped off asa resultof using anelectricalappliance,the cause
can
be an overload or a short-circuit. In sucha case, stop operationimmediatelyand carefully
check theelectricalapplianceandAC
plugs for faulty wiring.
- 14-

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 applianceis not always equal to the output watt-
age of the appliance. The electrical appliances generally have a label showing their rated voltage, fre-
quency, and power consumption (input wattage). The power consumption
of an electrical appliance is
the power necessary for using it. When using a generatorfor operating an electrical appliance,the power
factor and starting wattage must be taken into consideration.
Inorder to determine the right size generator,itis necessary to add the
total wattage of all appliancesto
be connectedtothe unit.
Refer to the followings to calculate the power consumption of each appliance or equipment by its type.
(1) Incandescent lamp, heater, etc. witha power factor of 1 .O
Total power consumption must be equal to or less than the rated output of the generator.
Example : A rated 3000W generator can turn thirty lOOW incandescent lamps on.
(2) Fluorescent lamps, motor driven tools, light electrical appliances, etc. witha smaller power
factor
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.
Example : A rated 250 W electric drill requires a 400 W generator to start it.
NOTE 7 : If a power factor correction capacitor is not applied to the fluorescent lamp, the more power
shall be required to drive the lamps.
NOTE2
: Nominal wattage of the fluorscent lamp generally indicates the output wattageof the lamp.
Therefore,
if the fluorescent lamp has no special indication as to the power consumption,efi-
ciency should be taken into account as explainedinitem
(5) on the following page.
(3)
Mercury lamps witha smaller power factor
Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.
Example : 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.
(4) Initially loaded motor driven appliances suchas water pumps,compressors,etc.
These appliances require large starting wattage whichis3 to 5 times of running wattage.
Example : A rated 900 W compressor requires a 4500 W generator to drive it.
NOTE 7 : Motor-driven appliances require the aforementioned generator output onlyattheshdng. Once
their motors are started, the appliances consume about
7.2 to 2 times their rated power con-
sumption
so that the excess power generated by the generator can be used forother electrical
appliances.
NOTE2
: Motor-driven appliances mentioned in Items(3) and (4) vary in their required motorsbrting
power depending on the kind of motor and start-up load.
if it is dficulttodetermine the optimum
generator capacw, select a generator with a larger capaciw.
- 15-

(5)Appliances without any indication as to power consumption
Some appliances have no indication asto power consumption; but instead the work load (output)is
indicated. In such a case, power consumptionisto beworked out accordingto the numerical formula
mentioned below. (Output
of electrical appliance)
(Efficiency)
= (Power consumpition)
Efficiencies of some electrical appliances are as follows
:
Single-phase motor ................................
Fluorescentlamp ................................... 0.7 to 0.8 lowertheefficiency.
Oe6 to 0-753(
The smaller the motor, the
Example 1: A 40W fluorescent lamp means that its luminous output is 40W. Its efficiencyis0.7 and
accordingly, power consumptionwill be
40 t 0.7= 57W. As explained in Item (2), multiply
this power consumption value of57
W by 1.2 to 2 and you will get the figure of the neces-
sary capacity of a generator. In other words, a generator with a rated output of 1OOOWcapacity
can light nine to fourteen 40 W fluorescent lamps.
Example 2 : Generally speaking, a 400 W motor means that its work loadis 400 W. Efficiency of this
motor is
0.7 and power consumption will be 400+0.7= 570 W. When this motoris used for
a motor-driven tool, the capacity of the generator should
be multiple of 570 W by 1.2to 3 as
explained in the Item
(3). 570 (W) x 1.2 to 3 = 684 (W) to 1710 (W)
MODEL RGD3300 RGD2500
Frequency
I I I
60 Hz 60 Hz
lncandesent lamp,
heater, etc.
I 22OOw I 30OOW
Fluorescent lamp, Motor-
2100 w
15OOW
driven tool, general-porpose approx.
approx.
~~~~~
Mercury lamp, etc.
approx. approx.
1 13OOW I 18WW
Pump, compressor, etc. approx.
approx.
1 650 W
Table. 7-1
- 16-

NOTES : Wringbetween generator and electrical appliances
I. Allowable current ofcable.
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
7-2 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 de-
creasing the input voltage to the load (electrical product). As a result, the load
can be damaged.Tabe
7-2 shows voltage drops per I00 meters of cable.
"
"
Sectional
area
/ mm3
0.75
1.25
2.0
3.5
5.5
Gauge No'
wire dement
Resistance
Voltage
A"owab'e
current
/ A
mm
Ohm/100m
1~ 3~ 5~
7 I 3010.18 I 2.477 I 2.5 V I 8 V 112.5 V
12 50 10.18
1.486 1.5V 5V 7.5V
17 3710.26
0.952 1.0 V 3V 5.0 V
23 I 45/0.32 I
0.517
I I 1.5V I 2.5 V
Table. 7-2
Voltage drop indicatesas V= - x R x I x L
1
100
drop per 100 m
4V I 5V 16.5V
2.5v I 35-v I 4 v
7.5 v I
5v I
R meansresistance ( hz / 100 m)on the abovetable.
I meanselectriccurrentthroughthewire (A).
L meansthelength of thewire (m).
The length of wire indicaters round length, it means twice the length from generator to electrical tools.
- 17-