Robin RGX1800 User manual

z&or
Model RGXl80
RGX35OOlR
evised]
IISSUE 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 ofGenerator .......................................................... 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
10-3 Disassembly Procedures .............................................................. 53
10-4 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 11OVl22OV
_---_. .- - --.-.....- ._-.- .,
12OV/24OV 12.5Al6.3A .-~ -- .i--
. .._ -_---__A._. --.. ._ .-- -.. .-_-.. . _--.
1.o
.- .--. _ -~ _._..,,,,,---- _._,.- - .--._ .-_-. ..--
12V-8.3A (1OOW)
-- .. __--_- . ,-_-- __,...__ ..---_ ,.,...--. . __ -,.
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
-..-_-,- -_._-_-
11OVl22OV 22.7Al11.4A 11OVl22OV 26.4Al13.2A 11OVI22OV 40Al20A 11OVi22OV 43.6A121.8A
_.,__-.. --.. -.. .-.-
-_ - 12OVl24OV 24.2Al12.1A - -’ - 12OVI24OV 40Al20A
-..- _--__-- __._,, ., -,. .---. .- -.----- --.-
1.0
_-_.._. . ,. ..~- _______ -.-,.---- -..-_
12V-8.3A (1OOW)
..---... ._____ -.----,-. --.------. -_--
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 ...................... 11ov/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 E2
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-

CURREIQT (AI-
i i 1
I , .I I I I III1 I
0 10 20 30
CURRENT (Al-
1 62
-;= 61
7 60
v
2
u 59
z 240
z
‘A 220
RGX3500
Output Max. ...................... 3(yJ(-Jw
Rated ..................... 25oow
Frequency ........................ 50Hz
Voltage ........................... 24ov
RGX3500
Output Max. ...................... 35(-Jaw
Rated .................. *.. 3oo()w
Frequency ........................ 50Hz
Voltage ...................... 11ov/22(-jv
RGX3500
Output Max. ...................... 35oow
Rated ..................... 3o()()w
Frequency.. ...................... 60Hz
Voltage ...................... 11ov/22ov
0 10 20 30
CURREXT IA,-
- 10 -

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
5252
5151
soso
4949
2:
240240
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
-4kt
-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 ...................... 11ov/22()v
RGXSSOO
Output Max. ...................... 55OOW
Rated ..................... 48()()W
Frequency ........................ fj(-)Hz
Voltage ...................... 11ov/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
zd 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 abattery.
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.
l 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-11OV, 6OHz-120V TYPE
DC
VOLTMETER
FUSE
CIRCUIT BREAKER
- AC RECEPTACLE
\
DC OUTPUT TERMINAL ‘EARTH (GROUND) TERMINAL
l
RGX2400 : SOHz-11OV, 60Hz-120V TYPE
VOLTMETER
0
CIRCUIT BREAKER
+ AC RECEPTACLE
\
DC OUTPUT TERMINAL EARTH (GROUND) TERMINAL
-17-