Subaru ROBIN RGD3300H User manual

SERVICE
MANUAL
RGD3300H
RGD5000H
GENERATORS
Models
PUB-GS2380
Rev. 06/08

CONTENTS
Section Title Page
1. SPECIFICATIONS ................................................................................. 1
2. PERFORMANCE CURVES.................................................................. 2
3. GENERAL DESCRIPTION
3-1 External View................................................................................... 3
3-2 Control Panel................................................................................... 4
3-3 Serial Number and Specification Number........................................ 4
4. CONSTRUCTION AND FUNCTION
4-1 Construction .................................................................................... 5
4-2 Function........................................................................................... 5
4-3 Generator Operation........................................................................ 9
5. SAFETY PRECAUTIONS..................................................................... 12
6. RANGE OF APPLICATIONS ............................................................... 13
7. MEASURING PROCEDURES
7-1 Measuring Instruments .................................................................... 16
7-2 AC Output Measuring ...................................................................... 17
7-3 Measuring Insulation Resistance..................................................... 18
8. CHECKING FUNCTIONAL MEMBERS
8-1 AC Receptacles ............................................................................... 19
8-2 Circuit Breaker ................................................................................. 19
8-3 Stator ............................................................................................... 20
8-4 Rotor Assembly ............................................................................... 20
8-5 Condenser ....................................................................................... 21
8-6 Diode Rectifier ................................................................................. 22
9. DISASSEMBLY AND ASSEMBLY
9-1 Preparation and Precautions ........................................................... 23
9-2 Special Tools for Disassembly and Assembly ................................. 23
9-3 Disassembly Procedures................................................................. 24
9-4 Assembly Procedures...................................................................... 33
9-5 Control Box...................................................................................... 42
10. TROUBLE SHOOTING
10-1 No AC Output .................................................................................. 43
10-2 AC Voltage is Too High or Too Low.................................................. 45
10-3 AC Voltage is Normal at No-load, but the Load Cannot be Applied. 46
10-4 No DC Output .................................................................................. 47
11. WIRING DIAGRAM ............................................................................... 48
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1. SPECIFICATIONS
Specifications are subject to change without notice.
Model RGD3300H RGD5000H
GENERATOR
Type Brushless, self-exciting, 2-poles, single phase
Voltage regulator Condenser type
AC output
Frequency (Hz) 60
Rated voltage (V) 120, 120/240
Rated output (VA) 3000 4500
Maximum output (VA) 3300 5000
DC output (V-A) 12-8.3
Power factor 1.0
Over current protector No-fuse Breaker
Noise level at rated output (dB-7 m) 77.5 79.7
ENGINE
Model 1B30 1B40
Type Air-cooled, 4-cycle, single cylinder diesel engine
Displacement (ml) [cu. in.] 347 [21.17] 462 [28.19]
Fuel Automobile diesel light oil
Fuel tank capacity (L) [US gal.] 12.0 [3.17]
Continuous operating hours at rated output (h) 8.5 5.9
Starting system Electric and Recoil starter
Dimensions L × W × H (mm) [in.] 790 × 515 × 576 [31.10 × 20.28 × 22.68]
Dry Weight (kg) [lb] 87 [191.8] 104 [229.3]
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2. PERFORMANCE CURVES
2-1 MODEL RGD3300H
RGD3300H
Output Max............................3300 W
Rated .........................3000 W
Frequency .................................60 Hz
Voltage ...................................... 110 V
2-2 MODEL RGD5000H
RGD5000H
Output Max............................5000 W
Rated .........................4500 W
Frequency .................................60 Hz
Voltage ...................................... 110 V
2-3 DC OUTPUT (RGD3300H, RGD5000H)
DC Voltage ..................................12 V
DC Ampere ................................8.3 A
DC Output ................................100 W
The voltage curve shown in the left indi-
cates the characteristic of DC output when
charging a battery.
The voltage may be decreased by 20%
when the resistance load is applied.
NOTE: It is possible to use both DC and
AC outputs simultaneously up
to the rated output in total.
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3. GENERAL DESCRIPTION
3-1 EXTERNAL VIEW
FUEL COCK
AIR CLEANER
RECOIL STARTER
RECOIL STARTER HANDLE
FUEL GAUGE TANK CAP
FUEL TANK
CONTROL PANEL
OIL GAUGE (OIL FILLER)
SPEED ADJUSTER
OIL FILTER
OIL DRAIN PLUG
FUEL FILTER
ELECTRIC STARTER
MUFFLER
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3-2 CONTROL PANEL
●RGD3300H/5000H: 60 Hz-120 V, 240 V TYPE
3-3 SERIAL NUMBER AND SPECIFICATION NUMBER
Serial number and Production number are indicated on the labels stuck on the rear cover.
Specification label is attached on the frame.
NOTE: Always specify these numbers when inquiring about the generator or ordering spare parts
in order to get correct parts and accurate service.
RGD3300H
AC RECEPTACLES (20 A)
VOLTMETER
FULL POWER
SWITCH
AC CIRCUIT
BREAKER
DC FUSE
HOUR METER
KEY SWITCH
GROUND TERMINAL
DC TERMINALS
AC CIRCUIT
BREAKER
AC RECEPTACLES (30 A)
PROD No. / SER No. (Label)
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4. CONSTRUCTION AND FUNCTION
4-1 CONSTRUCTION
4-2 FUNCTION
4-2-1 STATOR
The stator consists of a laminated silicon steel
sheet core, a main coil and a condenser coil which
are wound in the core slots.
The condenser coil excites the rotor field coil which
generates AC voltage in the main coil.
GENERATOR BASE
MOUNT RUBBER
STARTOR BOLT
REAR COVER
THROUGH BOLT
FRONT COVER
END COVER
BALL BEARING
STARTOR COMPLETE
SUPPORT RING
ROTOR COMPLETE
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4-2-2 CONDENSER
Two condensers are installed in the control box and
are connected to the condenser coil of the stator.
These condensers and condenser coil regulate the
output voltage.
4-2-3 ROTOR
The rotor consists of a laminated silicon steel sheet
core and a field coil which is wound over the core.
DC current in the field coil magnetizes the steel
sheet core. Two permanent magnets are provided
for the primary exciting action.
A diode rectifier and surge absorber is mounted inside of the insulator.
DIODE RECTIFIER SURGE ABSORBER
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4-2-4 FUSE
The 10 ampere DC fuse mounted on the control
panel protects whole DC circuit from getting dam-
age by overload or short circuit.
4-2-5 NO-FUSE BREAKER
The no-fuse breaker protects the generator from getting damage by overloading or short circuit in the
appliance. The table below shows the capacity of no-fuse breaker by each spec. and their object of pro-
tection.
MODEL SPECIFICATION NO-FUSE BREAKER OBJECT of PROTECTION
RGD3300H 120/240 V 14 A × 2 Total output amperage
RGD5000H 120/240 V 20 A × 2 Total output amperage
30 A Output from 30 A receptacle
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4-2-6 RECEPTACLE AND AC PLUG (STD. SPEC.)
These are used for taking AC output power from the generator. A total of three kinds of receptacles, each
varying in rated voltage and current from another, are used to deliver the rated generator output. As many
AC plugs as the receptacles, each matching the corresponding receptacle, are provided. The table below
shows the rated current for each receptacle. Be careful not to use the receptacles and AC plugs beyond
the specified limits to prevent burning.
CAUTION: To connect the appliance to locking receptacle, insert the plug into the receptacle and
turn it clockwise to lock.
NOTE: The generator for U.S.A. market is equipped with NEMA standard receptacles.
Use the proper plug for connecting appliance to the generator.
NOTE: If your generator has receptacles peculiar to your country, the table above does not apply.
Style Ampere Receptacle AC plug Description
125 V
20 A
NEMA
5-20R
NEMA
5-20P
GFCI
(Ground Fault Circuit lnterrupter)
Receptacle, duplex
125 V/250 V
20 A
NEMA
L14-20R
NEMA
L14-20P Locking Receptacle
125 V
30 A
NEMA
L5-30
NEMA
L5-30P Locking Receptacle
TWIST
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4-3 GENERATOR OPERATION
4-3-1 GENERATION OF NO-LOAD VOLTAGE
(1) When the generator starts running, the permanent magnet built-in to the rotor generates 3 to 6 V of
AC voltage in the main coil and condenser coil wound on the stator.
(2) As two condensers are connected to the condenser coil, the small voltage at the condenser coil
generates a minute current which flows through the condenser coil. At this time, a small flux is
produced with which the magnetic force at the rotor’s magnetic pole is intensified. When this mag-
netic force is intensified, the respective voltages in the main coil and condenser coil rise up. 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 in the 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 mag-
netizes the rotor core to generate an output voltage in the main coil.
(4) When generator speed reaches 3000 to 3300 rpm (60 Hz type), the current in the condenser coil
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 reach to the rated value.
4-3-2 VOLTAGE FLUCTUATIONS UNDER LOAD
When the output current flows through the main coil to the appliance, a magnetic flux is produced 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 generator
output voltage is prevented from decreasing.
ROTOR
DIODE
FIELD COIL
SURGE
ABSORBER
PERMANENT MAGNET
FOR INITIAL EXCITATION STATOR MAIN COIL
RECEPTACLE
APPLIANCE
CONDENSER
CONDENSER COIL
a
a
c
a a
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4-3-3 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 recep-
tacle in each voltage.
Fig. 1
Fig. 2
Switch
Position
LOWER VOLTAGE
RECEPTACLE
HIGHER VOLTAGE
RECEPTACLE
120 V Rated output No output can be taken.
120/240 V Half of rated output Rated output
Table A
MC1
MC2
Rec. 1
Rec. 2
120 V
120 V
Rec. 3
120 V
120/240 V
240 V
MC1
MC
2
Rec. 1
Rec. 2
120 V 120 V
MC
1
MC2
Rec. 1
Rec. 2
120 V
120 V
Rec. 3
240 V
Fig. 3
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lnside the generator are two sets of main coils. Each main coil outputs half the rated power at the lower
voltage (120 V). These main coils are wound to be in the same phase. The full power switch reconnects
these main coils in parallel or in series.
Fig. 1 shows a circuit diagram. When the full power switch is set for single lower voltage indication (120
V), the switch position is as indicated by the lower solid line in the diagram. Fig. 2 is a simplified represen-
tation of this circuit, showing the two main coils connected in parallel. ln this case, the higher voltage (240
V) at Rec. 3 cannot be taken out. Rec. 2 for the lower voltage can output up to the rated power (up to 30 A
if the rated current is over 30 A), and Rec. 1 can output up to a total of 15 A.
When the full power switch is set for double voltage indication (120 V/240 V), the switch position is as indi-
cated by the upper dotted line in Fig. 1. Fig. 3 is a simplified representation of this circuit, showing the two
main coils connected in series. ln this case, power can be taken simultaneously from the receptacles for
the both voltages. Rec. 3 for the higher voltage can output up to the rated power, but Rec. 1 and Rec. 2 for
the lower voltage can output only up to half the rated power each.
Table A is a summary of the above explanation. Select the proper output voltage by full power switch in
accordance with the appliance to be used.
4-3-4 VOLTAGE CHANGEOVER SWITCH
The generator of 50 Hz 110 V/220 V dual voltage type for U.K. is provided with voltage changeover switch
instead of full power switch.
The output voltage is selected from 110 V and 220 V by turning this switch and both voltages cannot be
taken out simultaneously.
The middle point of the main coil shall be grounded when the changeover switch is turned to 110 V side.
Fig. 4
110 V
RECEPTACLE
VOLTAGE
CHANGEOVER
SWITCH
220 V
RECEPTACLE
NFB
NFB
32 A
16 A
MAIN COIL
MAIN COIL
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5. SAFETY PRECAUTIONS
(1) Use extreme caution near fuel. A constant danger of explosion or fire exists.
Do not fill the fuel tank while the engine is running. Do not smoke or use open 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 inflammable materials near the generator.
Be careful not to put fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near
the generator.
(3) Do not operate the generator in a room, cave or tunnel. Always operate in a well-ventilated
area.
Otherwise the engine may overheat and also, the poisonous carbon monoxide contained in the
exhaust gases will endanger human lives. Keep the generator at least 1 m (4 feet) away from struc-
tures or facilities during use.
(4) Operate the generator on a level surface.
If the generator is tilted or moved during use, there is a danger of fuel spillage and a chance that the
generator may tip over.
(5) Do not operate with wet hands or in the rain.
Severe electric shock may occur. If the generator is wet by rain or snow, wipe it and thoroughly dry it
before starting.
Do not pour water over the generator directly nor wash it with water.
If the generator is wet with water, the insulations will be adversely affected and may cause current
leakage and electric shock.
(6) Do not connect the generator to the commercial power lines.
This may cause a short-circuit or damage to the generator. Use a transfer switch for connecting with
indoor wiring.
NOTE: The parts numbers of the transfer switches and of the plastic box to store them are
as shown in the table below.
(7) Use a fuse of the correct capacity. (DC output)
If the generator rpm is increased excessively in the overload condition by using an over rated fuse,
the generator may be burnt.
CAUTION: If the fuse is burnt out or the circuit breaker tripped off as a result of using an
electrical appliance, the cause can be an overload or a short-circuit. In such a
case, stop operation immediately and carefully check the electrical appliance and
AC plugs for faulty wiring.
Part No. Part Name Q’ty Phase Allowable Current
365-45604-08 Transfer Switch 1 1 15 A
367-45605-08 Transfer Switch 1 1 30 A
340-45606-08 Transfer Switch 1 1 60 A
367-43008-08 Plastic Box 1 1 30 A
348-43009-08 Plastic Box 1 1 60 A
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6. RANGE OF APPLICATIONS
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.
(1) Incandescent lamp, heater, etc. with a power factor of 1.0
Total power consumption must be equal to or less than the rated output of the generator.
Example: A rated 3000 W generator can turn thirty 100 W incandescent lamps on.
(2) Fluorescent lamps, mercury lamps, etc. with a smaller power factor
Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the
load.
Example: A 400 W mercury lamp requires 600 W to 700 W power source to be turned on.
A rated 3000 W generator can power four or five 400 W mercury lamps.
NOTE 1: If a power factor correction capacitor is not applied to the mercury lamp or fluores-
cent lamp, the more power shall be required to drive those lamps.
A rated 3000 W generator can drive one or two 400 W mercury lamps without power
factor correction capacitors.
NOTE 2: Nominal wattage of the fluorescent lamp generally indicates the output wattage of
the lamp.
Therefore, if the fluorescent lamp has no special indication as to the power con-
sumption, efficiency should be taken into account as explained in Item (5) on the
following page.
(3) Motor driven tools and light electrical appliances
Generally the starting wattage of motor driven tools and light electrical appliances are 1.2 to 3 times
larger than their running wattage.
Example: A rated 250 W electric drill requires a 400 W generator to start it.
(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.
These appliances require the large starting wattage which is 3 to 5 times of running wattage.
Example: 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 capac-
ity.
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(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 such a case, power consumption is to be worked out according to the numerical for-
mula mentioned below.
Efficiencies of some electrical appliances are as follows:
Example 1: A 40 W fluorescent lamp means that its luminous output is 40 W. Its efficiency is 0.7 and
accordingly, power consumption will be 40 ÷ 0.7 = 57 W. As explained in Item (2), multi-
ply this power consumption value of 57 W by 1.2 ~ 2 and you will get the figure of the
necessary capacity of a generator. In other words, a generator with a rated output of
1000 W capacity can light nine to fourteen 40 W fluorescent lamps.
Example 2: 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 multipled by 1.2 to 3 and
570 W as explained in the Item (3).
(Output of electrical appliance) = (Power consumption)
(Efficiency)
Single-phase motor ............... 0.6 ~ 0.75 The smaller the motor, the lower the efficiency.
Three-phase motor................ 0.65 ~ 0.9
Fluorescent lamp................... 0.7 ~ 0.8
MODEL RGD3300H RGD5000H
Frequency 60 Hz 60 Hz
Incandescent lamp, heater, etc. 3,300 W 4,500 W
Fluorescent lamp, mercury lamp, etc. approx.
2,200 W
approx.
3,000 W
Motor-driven tool, general-purpose motor, etc. approx.
1,900 W
approx.
2,700 W
Water pump, compressor, etc. approx.
950 W
approx.
1,300 W
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NOTES: Wiring between generator and electrical appliances
1. Allowable current of cable
Use a cable with an allowable current that is larger than the rated input current of the load
(electrical appliance). If the input current is larger than the allowable current of the cable
used, the cable will become excessively heated and deteriorate the insulation, possibly
burning it out.
The table below shows cables and their allowable currents for your reference.
2. Voltage drop in long electric extension cords
When a long wire is used to connect an appliance with the generator, a certain amount of
voltage drop occurs in the wire which lessens effective voltage available to the appliance.
The table below has been prepared to illustrate the approximate voltage loss when an
extension cord of 300 feet (approx. 100 meters) is used to connect an appliance or tool to
the generator.
R means resistance (Ω/100 m) on the above table.
l means electric current through the wire (A).
2means the length of the wire (m).
The length of the wire indicates round length, it means twice the length from generator to electrical
tools.
Nominal
cross
section
A.W.G.
Gauge
No.
Allowable
current
No. of
strands/strand
dia.
Resistance Current Amp.
mm2No. A No./mm Ω/100 m 1 A 3 A 5 A 8 A 10 A 12 A 15 A
Voltage drop
0.75 18 7 30/0,18 2.477 2.58V12.5V————
1.27 16 12 50/0.18 1.486 1.5 V 5 V 7.5 V 12 V 15 V 18 V —
2.0 14 17 37/0.26 0.952 1 V 3 V 5 V 8 V 10 V 12 V 15 V
3.5 12 ~ 10 23 45/0.32 0.517 — 1.5 V 2.5 V 4 V 5 V 6.5 V 7.5 V
5.5 10 ~ 8 35 70/0.32 0.332 — 1 V 2 V 2.5 V 3.5 V 4 V 5 V
Voltage drop indicates as V = 1× R × I ×2
100
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7. MEASURING PROCEDURES
7-1 MEASURING INSTRUMENTS
7-1-1 VOLTMETER
AC voltmeter is necessary. The approximate AC
voltage ranges of the voltmeters to be used for vari-
ous types of generators are as follows:
0 to 150 V: Type with an output voltage of 120 V
0 to 300 V: Type with an output voltage of 240 V
0 to 150 V, 0 to 300 V: Dual voltage type
7-1-2 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)
7-1-3 FREQUENCY METER
Frequency range: About 45 to 65 Hz
NOTE: Be careful of the frequency meter’s
input voltage range.
7-1-4 TESTER
Used for measuring resistance, etc.
FOR AC
FOR AC
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7-1-5 MEGGER TESTER
Used for measuring generator insulation resis-
tance.
Select one with testing voltage range of 500 V.
7-1-6 TACHOMETER
There are various types of tachometers, such as
contactless type, contact type, and strobe type. The
contact type can be used only when the generator
and engine have been disassembled. The contact-
less type is recommended.
7-2 AC OUTPUT MEASURING
Use a circuit like the one shown in the figure 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 table below at the rated amperage and rated rpm.
Rated voltage 120 V 240 V
Voltage range 117 ~ 130 V 235 ~ 260
CONTACT TYPE
STROBE TYPE
CONTACTLESS TYPE
LOAD
SWITCH
TO AC RECEPTACLE
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