Yamaha EF3000iSE - Inverter Generator - 3000 Maximum AC... User manual

YAMAHA GENERATOR
NEW MODEL GUIDE
EF3000iSE
EF3000iSEB
YAMAHA MOTOR CO., LTD
O.P.E. OPERATIONS
SERVICE GROUP
March 2003
318040
EF3000iSE new model guide 3/14/03 4:20 PM Page 0-1

CONTENTS
INVERTER SYSTEM
Benefits of an inverter generator EF3000iSE .......................................1
Multi-pole alternator features................................................................1
Control unit ...........................................................................................2
Inverter system of EF3000iSE ..............................................................2
Principles of power generation with an inverter generator...................2
Function of control unit ........................................................................3
Electronic governor ...............................................................................3
Function of electronic governor............................................................4
Throttle motor .......................................................................................4
Economy control operation and features ..............................................4
Continuous running time.......................................................................5
Frequency variation...............................................................................6
Voltage variation....................................................................................6
Instantaneous frequency fluctuation & instantaneous voltage drop .....6
Electronic breaker .................................................................................7
GENERATOR
Cooling system......................................................................................8
Control panel.........................................................................................9
Indicators...............................................................................................9
Overload warning lamp......................................................................9
Output indicator ...............................................................................10
Oil warning lamp .............................................................................10
Covers..................................................................................................10
DC 12 V output ...................................................................................11
Battery charging ..................................................................................12
ENGINE
Engine..................................................................................................16
Ignition system ....................................................................................16
Oil warning system .............................................................................17
Auto de-compressor system ................................................................17
TECHNICAL TIPS
Fuel tank removal................................................................................18
Engine oil replacement........................................................................19
Air cleaner & carburetor .....................................................................20
MF battery...........................................................................................21
APPENDIX
Special tools ........................................................................................22
Wiring diagram....................................................................................23
External views of the EF3000iSE .......................................................26
Serial number ......................................................................................26
Specifications ......................................................................................27
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Introduction
The EF3000iSE is the first Yamaha generator to use our exclusive inverter system (microcomputer-controlled
sine wave inverter) packed in a soundproof case, and designed in response to the diverse needs of the market
today.
With the adoption of the inverter system, it supplies high quality electricity equivalent to household power sup-
ply.
The EF3000iSE uses the same highly reputed and reliable MZ175 engine used on EF2600 for the USA and
EF2300 for Europe.
Air intake Fuel tank cap Fuel gauge
Recoil starter Control panel Service hatch Exhaust MF Battery Service hatch
Main switch Economy control switch DC output AC receptacles
Fuel pet cock Choke knob Oil warning lamp
Output indicator
Over load indicator
USA specification
    
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– 1 –
Benefits of an inverter generator EF3000iSE
The EF3000iSE realizes a new, high-level standard of quality that breaks the mold of the conventional gener-
ator image.
In terms of basic functions, the EF3000iSE achieves:
1. quiet, pleasant operating sound of 51dBA/7m at 1/4 rated load,
2. a continuous running time of 20.5 hours at 1/4 rated load,
3. sine wave AC supply (waveform distortion ratio of less than 2.5%)
4. controls concentrated on one panel.
5. a lightweight, compact body of just 64 kg and equipped with four wheels for easy moving,
In addition, the EF3000iSE is packed full of convenient design features throughout, such as large fuel tank
filling mouth, outstanding easy starting. The EF3000iSE is also a model that can be used for a wide range of
applications, even able to supply sine wave AC current to a UPS, Uninterruptible Power Supply.
Multi-pole alternator features
The combination of ferrite magnets in the rotor and
multi-pole stator provides compact and high perfor-
mance alternator.
High-frequency multi-pole alternator features:
16-pole rotor
24-pole stator coil
3-phase AC power generation
Reference information:
Ferrite magnets are magnetically stable and have a
strong coercive force and so do not become demagne-
tized. While they have excellent corrosion resistance,
they are also brittle due to the way they are produced.
Great care must be taken when assembling them as jar-
ring or shocks of force can adversely affect their effi-
ciency.
Exhaust pipe
Engine
Alternator
Muffler
Fuel tank
Control unit
Recoil starter
Battery
EF3000iSE/EF3000iSEB
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– 2 –
Control unit
The control unit is a sealed unit.
Functions:
AC power generation
Electronic governor (throttle control)
Economy control program
Self-protective function
Over current
Over voltage
High temperature
Inverter system of EF3000iSE
In the EF3000iSE, the control unit and multi-pole alternator cooperate to generate AC output. The inverter,
controlled by a 16-bit microcomputer, is a PWM sine wave inverter.
* PWM: Pulse Width Modulation
1. The generator’s output frequency remains unchanged even when the engine speed varies.
2. The output voltage is stable.
3. The output waveform is sine wave with distortion ratio of less than 2.5%, equivalent to household elec-
tricity.
Principles of power generation with an inverter portable generator
* An alternator that uses highly efficient ferrite magnets generates three-phase AC.
8120V model: AC 135 to 255V, 300 to 550Hz
8230V model: AC 260 to 488V, 300 to 550Hz
Control unit
*
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Power generation
Stage 1. The rectifier circuit converts three-phase AC into DC and it maintains stable DC voltage using a con-
stant voltage circuit
Stage 2. The Constant voltage DC current is stored in a condenser.
Stage 3. The PWM, pulse width modulator, inverter circuit generates a stable sine wave AC current.
Stage 4. The filter circuit further smoothen the sine wave of the AC current and reduce electrical noise.
Protective functions:
■Overload (over current) protection device
The control unit has similar function to conventional NFB. When the output current exceeds specified
amperage, AC output is interrupted within specified length of time.
■Overheat protection
When the internal temperature of the control unit becomes abnormally high, AC output is interrupted.
■Over-voltage protection device
AC output is interrupted when the excessive current flows into the generator from outside power source
causing to rise voltage in the control unit.
Other functions of control unit:
Throttle control............... Control unit commands throttle motor to adjust engine speed automatically in
accordance with the amount of the electrical consumption.
Electronic governor
An electronic governor takes the place of a convention-
al mechanical governor, and opens and closes the car-
buretor throttle valve electrically.
Components and functions:
■Inverter control unit
The control unit constantly monitors the AC output
from the control unit, and adjusts the throttle motor to
produce the necessary engine speed.
■Throttle motor (stepping motor)
The throttle motor receives pulses from the control unit
and opens or closes the throttle valve approximately 0.7
degrees per pulse.
Stepping motor
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Functions of electronic governor
The inverter control unit is preprogrammed with the
ideal engine speed settings in relation to electrical cur-
rent output, and uses these settings as a cross-reference
with the detected current output to control the throttle
motor (and consequently the throttle valve) to adjust
engine speed to an optimum level. Therefore, the
engine speed will always be at the appropriate level
according to the load on the system.
With an inverter generator, even if the engine speed
changes it has no effect on the output frequency.
The electronic governor system is maintenance-free as
it cannot be adjusted externally.
Throttle motor
Caution during resistance measurement:
Do not allow the lead wire of the tester to touch the next
terminal when measuring the resistance between termi-
nals.
Caution during assembly:
To prevent damage to the throttle valve when reassem-
bling the carburetor, re-install the carburetor with the
throttle valve fully opened.
Caution:
If the engine is difficult to start after the carburetor is
installed onto the engine, make the throttle valve fully
opened by hand and then start the engine.
Economy control operation and features
Because output frequency of an inverter generator is
unrelated to the engine speed, it becomes possible to
utilize a wide range of engine speed.
Therefore, it also becomes possible to use low engine
speed to meet a low electrical consumption.
With the EF3000iSE, the control unit commands the
throttle motor built into the carburetor to control the
throttle valve, which gives it the ability to continuously
control the engine speed, which in turn makes the econ-
omy control system possible.
However, economy control switch should be turned off in case of the following occasions.
1. When operating an electric motor, such as water pump, which requires a large starting current.
2. When the changes in voltage cannot be accepted.
3. When charging batteries.
– 4 –
Resistance 250ΩTerminal: F3-1, 3-5, 3-2, 3-4
500ΩTerminal: 1-5, 2-4
Throttle valve position:
During assembly: Close
During engine starting: Open
Economy Control Characteristics
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– 5 –
Economy switch ON : 2800 rpm (with no load)
Economy switch OFF: 3550 rpm
The engine will run at 2800 rpm with economy switch turned on, if the electrical consumption is below 1/4
of its rated output.
When a light and electric motor are connected to the generator at the same time, turning one of the devices on
and off causes a change in voltage and could have an adverse effect on the other device.
In these kinds of cases, first turn the economy switch off before use.
Throttle valve operation:
■The throttle valve is fully opened when the engine is not running.
■When the engine is started with no load, the throttle valve will be set in an almost completely closed
position as soon as the engine is started.
(When the economy switch is “ON”, it will be in a position to maintain 2800 rpm.)
■The engine speed will be adjusted according to the requirements of the load on the system.
■The throttle stops at the fully opened position when the engine is turned off in order to prepare for the
next attempt to start the engine.
In temperatures of zero degrees or below, the engine will automatically run at 3550 rpm for three minutes for
warming up purpose, even when the economy control switch is turned ON.
Continuous running time
EF3000iSE is able to run for 20.5 hours with 1/4 load
with fuel tank full, when economy control switch is on.
With rated load: 8.0 hours
With 1/4 load: 20.5 hours
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Frequency variation
In case of conventional synchronous generators, the
engine speed with no load is set at approximately 6 %
higher than rated engine speed (3600rpm for 60 Hz) to
maintain rated frequency when full rated load is
applied. This is the reason why no-load frequency is
slightly higher than rated frequency.
However, adapting an inverter system, which generates
genuine sine wave electricity, the frequency variation of
inverter generator is not influenced by the engine speed.
Therefore, an inverter generator provides constant AC
output frequency even if the load changes which is
equivalent quality to the commercial power supplies.
The frequency variation of EF3000iSE is less than 0.1 %.
Voltage variation
The output voltage with no load is approximately 10 %
higher than rated voltage in the case of conventional
synchronous type generators to achieve the rated volt-
age when full rated load is connected. Thus the voltage
variation occurs due to the change in engine speed and
the influence of the internal resistance.
However, adapting an inverter system, the voltage vari-
ation can be maintained minimum level, because the
output voltage cannot be influenced directly from
engine speed.
The voltage variation of EF3000iSE is smaller than 3%.
The waveform distortion rate of EF3000iSE is smaller than 2.5%.
Instantaneous frequency fluctuation & instantaneous voltage drop
■Momentary frequency fluctuation:
The frequency and voltage fluctuates momentary when
the load is altered if the engine cannot follow up the
load changes in the case of conventional synchronous
generators.
In contrast, the momentary frequency fluctuation of
EF3000iSE is as stable as the commercial power source
with this new inverter system.
The frequency fluctuation rate of EF3000iSE is less
than 0.1 %.
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– 7 –
■Momentary voltage drop:
However, the momentary voltage drop occurs, when large electric load is turned on.
This is caused by the fact that the electric energy stored in the condenser runs short momentarily until the
engine speed picks up to sufficient engine speed to compensate the energy shortage in the condenser.
The ratio of such momentary voltage drop and the rated voltage is defined as momentary voltage drop rate.
The momentary voltage drop rate of EF3000iSE is less than 20 %.
Naturally, the smaller the load capacity is applied, the smaller the momentary voltage drop becomes.
In case of incandescent lamps, large amount of rush current flows in the moment it is switched on. The rush
current may be as large as 10 times the rated current of the lamp. Therefore, when a large wattage incandes-
cent lamp(s) is switched on, the momentary voltage drop is greater.
■Settling Time:
It takes some duration to compensate the voltage from the momentary voltage drop by revving up the engine.
This duration is called settling time. In case of an EF3000iSE, the settling time is shorter than 2 seconds, when
a maximum rated load is turned on.
Electronic beaker
As opposed to the NFB used in synchronous type gen-
erators, the EF3000iSE uses an electronic breaker cir-
cuit housed in the control unit. When output from the
control unit exceeds a specific limit, output is automat-
ically interrupted to protect the generator from damage.
The control unit is designed to continuously monitor
the output current for overloads, and if the current over-
load continues longer than a specified time, output is
interrupted.
When using induction motors or similar devices (such
as underwater pumps) which require a large starting
current with the generator, the current will not be inter-
rupted even if the starting current exceeds several times
the generator’s rated output. Only when the large over current continues longer than a specified time, the con-
trol unit will interrupt the circuit, and in this way it resembles a mechanical NFB.
The engine must be stopped and power interrupted to the control unit in order for the system to reset after the
electronic breaker has activated.
An AC switch is not provided on the EF3000iSE, as it does not use a conventional magnetic type NFB.
Be sure the power switches on devices are OFF before connecting them to the EF3000iSE. After starting the
generator and the engine has warmed up, turn on the connected devices.
If a device’s power switch is ON when it is connected the generator and the generator is subsequently started,
the device may unexpectedly activate or start up as a result, creating a potentially dangerous situation.
Characteristics of Electronic Breaker
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