Robin RGD500 User manual

MAN,UAL
Model
RGD5000
Generator
PUB-GS1187
Rev. 8198

.
CONTENTS
*-
”
section nt/e Page
1 . SPECIFICATIONS ....................................................................................................... 1
2 . PERFOMANCE CURVES ........................................................................................... 2
2-1 MODEL RGD5000 .................................................................................................. 2
2-2
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
GENERATOROPERATION ................................................................................ 11
6 . SAFETY PRECAUTIONS ......................................................................................... 14
7 . RANGE OFAPPLICATIONS .................................................................................... 15
8 . MEASURING PROCEDURES .................................................................................. 18
8-1
MEASURINGINSTRUMENTS ........................................................................... 18
8-2
AC OUTPUT MEASURING ................................................................................. 21
8-3
DC OUTPUTMEASURING ................................................................................. 21
8-4
MEASURING INSULATION RESISTANCE ........................................................ 22
9 . CHECKING FUNCTIONAL MEMBERS .................................................................... 24
9-1
VOLTMETER ....................................................................................................... 24
9-2
AC RECEPTACLES ............................................................................................ 24
9-3
NO-FUSEBREAKER ........................................................................................... 24
9-4
STATOR .............................................................................................................. 25
9-5 ROTORASSEMBLY ........................................................................................... 26
9-6
CONDENSER ..................................................................................................... 27
9-7
DIODE RECTIFIER ............................................................................................. 27
10
. DISASSEMBLY AND ASSEMBLY .......................................................................... 29
10-1 PREPARATION and PRECAUTIONS ............................................................... 29
10-2
SPECIAL TOOLS for DISASSEMBLY and ASSEMBLY .................................... 29

Section Tile paw
10-3 DISASSEMBLY PROCEDURES ....................................................................... 30
10-4ASSEMBLY PROCEDURES ............................................................................. 39
10-5CHECKING. DISASSEMBLY and REASSEMBLY of the CONTROL BOX ....... 50
11 . TROUBLESHOOTING ............................................................................................ 52
11 -1 NO AC OUTPUT ................................................................................................ 52
11-2AC VOLTAGE
IS TOO THIGH OR TOO LOW ................................................... 54
11-3
AC VOLTAGE IS NORMALAT NO-LOAD. BUTTHE LOAD CANNOT BE APPLIED ..... 55
11-4 NO DC OUTPUT ............................................................................................... 56
12 . WIRING DIAGRAM ................................................................................................. 57

Model RGD5000
JYPe Brushless, Self
Exciting, 2-Pole, Single Phase
Frequency
4500 W Rated Output
AC
5000 W Maximum Output
60 Hz
120 v
37.5 A
12OV/24OV
I
Current
I 37.5N18.814
I I
I
Power Factor
VoltageRegulator
I CondenserType
12V-8.3
A (100 W)
DC Output
1
.o
Air-Cooled 4-Cycle, Diesel Engine
a
5
g!
51 a
1
[I W
1
-
t
c
1
Dimensions (L x W x H)
Dry Weight 95 kg (209 Ibs.)
I
26.5 x 19.7 x 21.3 in (675 x 500 x 542 mm)
Electric starter motorisavailable as option.
Model
8.5 HP / 3600 rpm
Rated
Output
412 cm3 (25.14 cu. in.)
Displacement
DY41 D
~
Fuel
~~ ~ ~~
Diesel light oil
Fuel Tank Capacity
~~~ ~ ~
4.2 U.S. gal. (16.0 liters)
Rated CoutinuousOperation 1
1
2.0 hours I
Oil Capacity
StartingSystem
i RecoilStarterand Electric Starter
2.3
US. gal. (1.1 liters)
- 1-

2. PERFOMANCE CURVES
2-1 MODEL RGD5000
t
-63
62
61
P
zi
E
-
*
=60
Y
K 59
1 130
s: 120
-
g 110
2
h
3
0 10 20 30 40 50
5k
4k t
-
2k 2
c
3
c
lk 0
0
CURRENTO -
2-2 DC OUTPUT
- = I6
Lu
14
12
g IO
0246810
CURRENT(A) -
Output Max. ................. 5000 W
Output Rated ............... 4500 W
Frequency .................... 60 Hz
Voltage ......................... 120 V
Output Max. ..............
5000 W
Output Rated ............
4500 W
Frequency .................
60 Hz
Voltage ...................... 120 Vl24OV
DC Voltage .................. 12 V
DC Ampere ................. 8.3 A
DC output .................... 100 W
The voltage cuwe 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.FEATURES
3-1 BRUSHLESSALTERNATOR
Newly developed brushlessalternator eliminatestroublesome brush maintenance.
3-2 EASY STARTING
Light pull recoil starter accompanied with automatic decompressionsystem makes the new RGD series
generators even easier instarting than gasoline engine generators.
3-3 QUIET OPERATION
The new RGD seriesgenerator providesquiet operation by means of:
The superbdesign of intake-exhaust system.
Direct injection combustion system.
0 A large supersilent muffler.
An efficient low noiseair cleaner.
3-4 ECONOMICALPERFORMANCE
On top of well known diesel economy, the air-cooled Robin diesel enginefeatures direct fuel injection
and special design refinements for extra fuel efficiency.
3-5 OIL SENSOR
The OIL SENSOR automatically shuts the engine off wheneverthe oil level f& down below a safelevel
preventingengine seizure.
3-6 COMPACT, LIGHT WEIGHT
The combination of newly developed brushless alternator and air-cooledsingle cylinder Robin diesel
engineenablesthe new
RGD series generators to bevery compact in size and light in weight.
3-7 RELIABLE PERFORMANCE WITH MINIMAL MAINTENANCE
A brushlessalternator eliminates troublesome brush maintenance.
A dripproof alternator design.
A trouble free condenser voltage regulator.
A fuselesscircuit breaker.
A dust-proof oil-bath air cleaner.
The OIL SENSOR automatically shuts the engine off whenever the oil level falls down belowa safe
level preventing engine seizure.
3-8 LONG-LIFE DURABILITY
0 Compact and smooth running air-cooled Robin dieselengine lasts much longer than the gasoline
0 Trouble-free brushless alternator with condenser type voltage regulator works all the year round
engine of the same size.
without any maintenace work.
- 3-

4.GENERAL DESCRIPTION
4-1 EXTERNAL VIEW
Rocket cover Air cleaner
\ ACreceptack
\
Fuel gauge Tank cap
\
/
Muffler
- 4-

4-2 CONTROL PANEL
RGD5000 : 60HZ-l20V, 60Hz-l2OV/240V TYPE
Voltmeter Full power switch
AC
Earth terminal DC output 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.
e
NOTE : Always specify these numbers when inquiring aboutthe generator or ordering spare parts in
order toget correct parts and accurate service.
Serial number
- 6-

"
5CONSTRUCTIONAND FUNCTION
!j-lCONSTRUCTlON
Mount rubber
\ Starter pu"ey
Driving shaft
\
Generator base Stator bolt Ball bearing Adapter
Fig. 5-1
5-2 FUNCTION
5-2-1 STATOR
Thestatorconsists of alaminatedsiliconsteel I
sheet core,a main coil and a condenser coil which
are woundinthe core slots.
The condenser coil excites the rotor field coil which
generates
AC voltage in the main coil.
Fig. 5-2
- 7-

5-2-2 CONDENSER
One or two condensers are installedinthe con-
trol
box andare connected to the condenser coil
of the stator.
These condensers and condenser coil regulate
the output voltage.
5-2-3 ROTOR
The rotor consists of a laminated silicon steel sheet
core and
a field coil whichiswound over the core.
DC current in the field coil magnetizes the steel
sheet core.
Two permanent magnets are provided
for the primary exciting action.
Fig. 5-4
A diode rectifier and surge absorberismounted inside of the insulator.
Fig. 5-5A
- 8-
Fig. 5-5B

5-24 DC FUSE
(1) The 10 ampere DC fuse mounted on the con-
trol panel protectswhole
DC circuit from get-
ting damage by overload or short circuit.
(2) The 15 ampere DC fuse inthe control box pro-
tects the diode rectifier from getting damage
by reverse connection to the battery.
(Electric start model)
5-2-5 NO-FUSE BREAKER
L
Fig. 5-6
The no-fuse breaker protects the generator from getting damagebyoverloading or short circuit in the
appliance.Table 5-1 shows the capacity
of no-fuse breaker by each spec. and their object of protection.
/-
MODEL OBJECT
or PROTECTION
NO-FUSE BREAKER
SPECIFICATION
60 HZ-120 V
37.5 A
Total output amperage
RGD5000
30 A
Output from 30A receptacle
20Ax2
Total output amperage
60 HZ-120 V, 240V
30 A Output from 3OA receptacle
Table. 5-1
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-
ingreceptacle, 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 1 : If your generator has receptacles pecu-
liar to your country, Table
5-2 does not
apply.
NOTE
2 :The generator for U.S.A. market is
equipped with NEMA standard recep-
tacles shown in table
5-2.
Use the proper plug for connecting ap-
pliance to the generafoE
I'
W
Caution : To connect the appliance to locking
receptacle, insertthe plug into the re
ceptacle and turn it clockwise to lock
Fig. 5-8
style
Description
AC
plug Receptacle
Ampere
El
30A
@
20A
@
20A
GFCI
125V (Ground Fault
NEMA
NEMA
5-20R Circuit Interrupter)
5-20P Receptacle, duplex
125V/ 250V
NEMA
L14-20R
L14-20P
NEMA
Locking Receptacle
125V
NEMA
E-30 L5-30P
NEMA
Locking Receptacle
Table. 5-2
- 10-

PERMANENTMAGNETSTATOR
FOR INITIALEXCITATION ,-
FIELDCOIL I
APPLIANCE
"""I
"""",I
fig, 5-9
5-3-1GENERATlON Of NO-LOAD VOLTAGE
(1) When the generator starts running, the permanent magnet built-in to the rotor generates 3 to 6V of AC
voltage inthe maincoiland condenser coil wound on the stator.
(2) As one or two condensers are connected to the condenser coil, the small voltage at the condenser
coil generates
a minute current @I which flows through the condenser coil. At this time, a small fluxis
produced with which the magnetic force at the rotor's magnetic poleis intensified.When this mag-
netic forceis intensified, the respective voltages in the maincoiland condensercoil riseup.
As the
current
@$ 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 flux in the rotor changes. This
change
of magnetic flux induces AC voltage inthe field coil, and the diode rectifier in the field coil
circuit rectifies this
AC voltage into DC. Thus a DC current @ flows through the field coil and magne-
tizes the rotor coreto generate an output voltage in the main coil.
(4) When generator speed reaches 3000 to 3300 rpm, the current in the condensercoil and field coil
increases rapidly. This acts
to stabilize the output voltage of each coils. If generator speed further
increases to the rated value, the generator output voltage
will reachto 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
@I in the condenser coil. When current a 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 -

5-34 FULL POWER SWITCH (Dual Voltage Type)
The full power switch is provided for the dual voltage type to take out the full rated power from one
receptacle in each
voltage.
I
Fig. 5-10
L
\
3MCz
Fig. 5-11
/
w
Switch
RECEPTACLE RECEPTACLE Position
HIGHER VOLTAGE
LOWER VOLTAGE
110 v
1 lgv I Rated output
No output can be
taken.
1 1 om0 v
120/240 v
or
Rated output Half of rated output
Table. 54
- 12 -

.-
Two main coils are wound over stator core. Each main coil outputs half the rated power at the lower
voltage
(11OV or 120V). These main coils are wound to be in the same phase. Thefull power switch
reconnects these main coilsin parallel or in series.
Fig.
5-10 shows a circuit diagram. When the full power switch is set for single lower voltage indication
(11OV or 120V), the switch positionisas indicated by the lower solid linein the diagram. Fig. 5-11 isa
simplified representation of this circuit, showing the
two main coils connectedinparallel.ln this case, the
higher voltage
(220V or 240V) at Rec. 3 cannot be taken out. Rec. 2 for the lower voltage can output up
tothe rated power (upto 30A if the rated current is over 30A), and Rec. 1 can output uptoa total of 15A.
When the full power switch is set for double voltage indication (11OV/22OV or 120V/240V), the switch
positionis
as indicated by the upper dotted lineinFig. 5-1 0. Fig. 5-1 2 isa simplified representation of this
circuit, showing the
two main coils connectedinseries. In this case, power can be taken simultaneously
fromthe receptacles for the
both voltages. Rec. 3 for the higher voltage can output up to the rated power,
butRec.
1 and Rec. 2 for the lower voltage can output only upto half the rated power each.
Table
5-4 is asummary of the above explanation. Select the proper output voltage by full power switch in
accordance with the appliancetobeused.
- 13-

6. SAFETY PRECAUTIONS
1. Use extremecautionnearfuel. A constantdanger ofexplosion or fireexists. w
Do not fill the fueltank while the engineis running. Do not smokeor use opern flame near the fuel
tank. Be careful not to spill fuel when refueling.
If spilt, wipe it and let dry before starting the engine.
2. Do not place inflammablematerials near the generator.
Be careful nottoput fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near the
generator.
3. Do notoperatethegenerator in aroom,cave or tunnel. Always operate in a well-ventilatedarea.
Otherwisethe engine may overheat and also, the poisonous carbon monoxide containedinthe ex-
haust gases
will endanger human lives. Keep the generator at least 1 m (4 feet) away from structures
or facilities during use.
4.0perate the generator ona levelsurface.
If the generator is tilted or moved during use, there is a dangerof fuel spillage and a chance that the
generator maytip over.
5. Do notoperatewithwet handsor in therain.
Severe electric shock may occur.
If the generator is wet by rain or snow, wipeitand thoroughly dry it
before starting. Don’ t pour water over the generator directly nor wash it with water. If the generatoris
wet with water, the insulations will be adversely affected and may cause current leakage and electric
shock.
6. Do notconnect the generatortothe commercial power lines. 4
This may cause a short-circuit or damagetothe generator. Use a transfer switch (Optional parts) for
connecting with indoor wiring.
NOTE : The parts numbers of the trawferswitches and of the plastic box to store themare asshown in
Table 6-1.
Part No.
Allowable Current Phase
Qlty
Part Name
365-45604-08
15 A
1 1 Transfer Switch
367-45605-08
60 A
1
1
Transfer Switch 340-45606-08
30 A
1 1 Transfer Switch
367-43008-08
60
A 1 1 Plastic Box 34843009-08
30 A
1
1 Plastic Box
Table. 61
7. Be sureto checkand remedythe causeof circuitbreakertrippingbeforere-setting it on.
CAUTION
: If the circuitbreakertripped off as a result of using an electricalappliance,the cause
can bean overloador ashort-circuit. In sucha case, stop operation immediately and carefully
check the electricalapplianceandAC plugs for faulty wiring.
- 14-

Generally, thepowerratingof an electrical appliance indicates the amount of work that can be done by it.
The electric power required for operating an electrical applianceisnot always equal to the output watt-
age of the appliance.Theelectrical appliances generally have a label showing their rated voltage, fre-
quency, and power consumption (input wattage). The power consumption of an electrical applianceis
the power necessaryfor using it. When using a generator for operating an electrical appliance,the power
factor and starting wattage must be taken into consideration.
Inorder to determinethe right size generator,
it is necessary to add the total wattage of all appliances to
be connected to the unit.
Refer
to the followingsto calculate the power consumption of each appliance or equipment by its type.
(1) Incandescent lamp, heater, etc. with a power factor of 1 .O
Total power consumption must be equalto or less than the rated output of the generator.
Example : A rated 3000W generator can turn thirty 1OOW incandescent lamps on.
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 andlight electrical appliances are
1.2 to 3
times lager than their running wattage.
Example : A rated 250 W electric drill requires a 400 W generatortostart it.
(2) Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power
NOTE7 : 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 wattage of the lamp.
Therefore,
if the fluorescent lamp has no special indication as to the power consumption, effi-
ciency should be taken into account as explained in Item
(5) on the following page.
(3) Mercury lamps with a 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 such as water pumps,compressors,etc.
These appliances require large starting wattage which is 3 to 5 times of running wattage.
Example : A rated 900 W compressor requires a 4500 W generatorto driie it.
NOTE7 : Motor-driven appliances require the aforementioned generator output only at the starting. Once
their motorsare started, the applianceswnsumeabout 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 motor starting
power depending
on the kind of motor and start-up load. If itis difficult to determine the Optimum
generator capacw,select
a generator with a larger capacity
- 15-

(5) Appliances without any indication as to power consumption
Some appliances have no indication as to power consumption; but instead the work load (output)is
indicated.
In suchacase,powerconsumption istobeworkedoutaccording to thenumericalformula UP
mentioned below. (Output of electrical appliance)
(Efficiency)
= (Power consumpition)
Efficiencies of some electrical appliances are
as follows :
Single-phasemotor ................................ 0.6 to 0.75 Thesmallerthemotor,the
Three-phasemotor
................................ 0.65 to 0.9 lowertheefficiency.
Fluorescent lamp
................................... 0.7 to 0.8
Example 1: A 40W fluorescent lamp meansthat its luminous outputis 40W. Its efficiencyis 0.7 and
accordingly, power consumption
will be 40 f 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 neces-
sary capacity
of a generator. In other words, a generator with a rated output of 1 OOOWcapacity
can light nine to fourteen 40 W fluorescent lamps.
Example 2 : Generally speaking, a 400 W motor means thatits work load is 400 W. Efficiency of this
motor is
0.7 and power consumption will be 400+0.7= 570 W. When this motorisused 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 Item (3). 570 (W) x 1.2 to 3 = 684 (W) to 171 0 (W)
MODEL
RGD5000
Frequency
60 Hz
lncandesent lamp,
heater,
etc.
4500 w
Fluorescent lamp, Motor-
driven tool, general-porpose I
approx.
3000 W
I
Mercury lamp, etc.
approx.
2700 W
I I
Pump, compressor, etc.
Table. 7-1
- 16-

NOTES : Wringbetween generator and electrical appliances
I. Allowable current of cable
Use a cableWhan allowable current that is higher than the rated input current of the load (electrical
appliance). If the input currentis higher than the allowable current
of the cable used, the cable will
become excessively heated and deteriorate the insulation, possibly burningit
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 canbedamaged. Table
7-2 shows voltage drops per 100 meters of cable.
Sectional
area
I mm3
I-
I 5.5
Allowable
current
I A
7
12
17
23
35
No’
wire element
NoJ mm
Resistance
30 10.18
50 I 0.1 8 1.486
37 I 0.26
0.517
70 I 0.32 0.332
Table. 7-2
Voltage drop indicates as V= - x R x I x L
1
100
R meansresistance ( 62 / 100 m) on theabove table.
I meanselectriccurrentthroughthewire (A).
L meansthelength of thewire (m).
The length of wire indicaters round length, it means twice the length from generatorto electrical tools.
- 17-