Subaru Robin Power Products 13OOOT manual

MANUAL Models RGVl2000 /13OOOT GENERATORS PUB-GS1328 Rev. Ol/OO[...]

CONTENTS Section Title Page 4.CONSTRUCTlONANDFUNCTlON l l l l l l l l l l l l l l l l l l 7 4-l CONSTRUCTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 J-2 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4-3 DESCRIPTION andGENERATOROPERATlON l . l l l l . . . l l l l l l 16 5. SAFETY PRECAUTIONS l o l l l[...]

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1. SPECIFICATIONS Model Type Rated frequency 8 Rated voltage E Q, Maximum output 2 . Rated output Power factor RGV12000 Brush, Self-exciting, 2-pole, Single phase 12OV I 240V 12OOOVA 1 OOOOVA 1.0 60Hz RGV13OOOT Brush, Self-exciting, 2-pole, 3-phase 12OV I 208V 13OOOVA 1 OOOOVA 0.8 Voltage regulator Model Type E Displacement z Maximum output W Fuel [...]

2. PERFORMANCE CURVES l RGV12000 / 60Hz (9.5 KW240V) (Hz) 63 HZ 62 .I1 61 60 ------------------------------------------ (VI 250 (125) 240 24OVl12OV (120) 230 (115) 220 (110) I/~~~~~~~~~ 112 Load ,--- 4/4 Rated . RGV13000T / 60Hz (12OW208V) (Hz) 63 62 61 60 230 T 220 t 208V 0 l/2 414 Load Rated -2-[...]

3. GENERAL DESCRIPTION OF GENERATOR TANK CAP iLTANK COOLING AIR / INLET PORT K /FUEL COCK BATTERY STOPPER OIL FILLER CAP SPARK PLUG CAP CHbKE KNOB (RGV13000T only) CONNECTOR FOR REMOTE CONTROL (RGV12000 only) END COVER (RGV13000T only) OIL GAUGE OIL DkAlN PLUG ‘ELECTRIC STARTER -3-[...]

CONTROL PANEL (RGVI 2000) OIL PURESSURE VOLT METER WARNING LAMP NO-FUSE BREAKER PILOT LAMP I HOUR METER EARTH (GROUND) CONNECTOR AC RECEPTACLE TERMINAL FOR REMOTE CONTROL (RGVI 3000T) OIL PURESSURE VOLT METER WARNING LAMP NO-FUSE BREAKER PILOT LAMP / HOUR METER KEY SWITCH c AUTO IDEL SWITCH :-. I EARTH (GROUND) TERMINAL KEY SWITCH AC RECEPTACLE[...]

SERIAL NUMBER Serial number is stamped on the label stuck on the end cover. NOTE : Always specify serial number when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service. (RGV13000T) (RGV12000) SERIAL NUMBER stamped label SERIAL NUMBER stamped label -5-[...]

4. CONSTRUCTION AND FUNCTION 4-l CONSTRUCTION END COVER BRUSH HOLDER (RGV13000T only) STATOR COMPLETE STATOR BOLT REAR COVER I ROTOR COMPLETE ‘y / I’ FRONT COVER BALL BEARING I TROUGH BOLT . . SLIP RING I MOUNT RUBBER 4-2 FUNCTION 4-2-l STATOR The stator consists of a laminated silicon steel sheet core, a main coil and a condenser coil [...]

4-2-2 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 (RGV13OOOT). Slip rings are provided on the rotor shaft to receive DC exciting current from AVR (RGV120[...]

4-2-4 CURRENT TRANSFORMER I DIODE UNIT (RGV13000T only) The current transformer and diode unit will perform a role to step up the voltage lowered by the load and stabilize the output voltage. CURRENT TRANSFORMER 4-2-5 A.V.R (AUTOMATIC VOLTAGE REGULATOR) (RGV12000 only) The automatic voltage regulator employs an electronic circuit to automatically r[...]

Function Warning lamp Electric starter control Fail-safe function Self checking function for warning lamp bulb Description of Operation When the lubrication oil pressure drops below the safety limit (Oil pres- sure becomes less than 1 kg/cm2), the warning lamp turns on and off, and the engine stops automatically. The warning lamp turns off after 3 [...]

4-2-8 OIL PRESSURE SWITCH The oil pressure switch sends a signal to ECU to stop the engine when the engine oil pressure drops to 1 .O kg/cm2 .r? 4-2-9 RELIEF VALVE The relief valve begins to open when the engine’s oil pressure increases above 3.0 kg/cm2 OIL FILTER I CAMSHAFT OIL PRESSljRE SWITCH OIL PUMP FILTER 4-2-10 AC SWITCH (NO-FUSE BREAKER) [...]

4-2-l 1 AC Receptacle and Terminals AC receptacle and terminals are used for taking AC output power from the generator. A total of 4 kinds of receptacle and terminals, each varying in rated voltage and current from. another, are used. As many AC terminals as the receptacles, each matching the corresponding receptacle, are provided. The rated curren[...]

n Check the amperage of the receptacles used referring to TABLE 1, and be sure not to take a current exceeding the specified amperage. n Be sure that the total wattage of all appliances dose not exceed the rated output of the gen- erator. Style Ampere up to20A Receptacle AC plug NEMA NEMA 5-20R 5-2OP Description GFCI (Ground Fault Circuit interrupt[...]

If the RESET button pops out during operation, stop the generator immediately and call a qualified electrician for checking generator and the appliances. (2) CONNECTING TO DOMESTIC CIRCUIT (HOUSE WIRING) All Robin generators are a neutral ungrounded type. If a generator is to be connected to residential or commercial power lines, such as a stand-by[...]

CONNECTING B RECEPTACLE c TRA&FER SWITCH m Ii .n .n 42-l 2 3-PHASE APPLICATION (RGV13OOOT only) Connection of Power Cables I n Do not touch output terminals while the generator is running or the operator may suf- fer severe electric shock resulting in death. w Be sure to shut down the generator before connecting or changing connection of power [...]

(1) 3-Phase application (208V) Connecting the power cable&o terminals U, V and W. 1 Generator rated output : 1OOOOVA 1 (2) Single phase higher voltage application (208V) Connect the power cables to-terminals U and V, V and W, and U and W. Maximum one-second (l/2) of generator output can be utilized from each phase. Generator rated output : 5760[...]

4-3 DESCRIPTION of GENERATOR OPERATION 4-3-l PRIMARY EXCITING ACTION (RGV12000) When the generator is started, the perma- nent magnet on the engine rotates to genera- tor a voltage in the exciting coil. This voltage is regulated by a diode in the AVR to feed a current to the generator field coil. (FC). (See Fig. 4-1) The rotor is turned an electrom[...]

4-3-3 CURRENT TRANSFORMER CONTROL (RGV13000T) When the engine starts, a permanent magnet implanted in the rotor rotates, creating voltage in the main coil (MC). When a load makes contact with the coil, the load current passing through the primary coil of current transformer causes a magnetizing current to flow in ratio to the load current flowing t[...]

5. SAFETY PRECAUTIONS 1. Use extreme caution near fuel. A constant danger of explosion or fire exists. r- 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 mate[...]

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 show- ing their rated voltage, frequency, [...]

NOTE 2 : Motor-driven appliances mentioned in lets (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 capaciv, select a generator with a larger capacity. .-. (5) Appliances without any indication as to power consumption Some appliances have [...]

NOTES : Wiring between generator and electrical appliances 1. Allowable current of cable 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 insui[...]

7. MEASURING PROCEDURES 7-l MEASURING INSTRUMENTS (1) VOLTMETER AC voltmeter is necessary. The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows : 0 to 150 V : Type with an output voltage ofllOor120V 0 to 300 V : Type with an output voltage of 220,230 or 240 V 0 to 150 V, 0 to 330 V : Dual vol[...]

(4) CIRCUIT TESTER Used for measuring resistance, etc. (5) MEAGER TESTER Used for measuring generator insulation resistance. Select one with testing voltage range of 5oov. 7-2 AC OUTPUT MEASURING TO AC Use a circuit above for measuring AC output. A hot plate or lamp with a power factor of 1 .O may be used as a load. Adjust-the load and rpm. and che[...]

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L_ . ROTOR a Measure the resistance between the slip ring and the core. . CONTROL PANEL Measure the insulation resistance between the live parts and the grounded parts. . CURRENT TRANSFORMER (RGV13000T) Measure the insulation resistance between each terminal and the core. If it is less than 1 M Q, replace the current transformer. Any part where the[...]

8. CHECKING FUNCTIONAL MEMBERS 6-l PILOT LAMP and VOLTMETER Check the pilot lamp and the voltmeter if it is turned on by applying specific voltage. Pilot lamp and voltmeter cannot be checked with circuit tester because its resistance is too large. 8-2 AC RECEPTACLES Using a circuit tester, check continuity between the two terminals at the rear of t[...]

8-3 AC SWITCH (NO-FUSE BREAKER) Check continuity between each of 2 terminals at the back side of AC switch (no-fuse breaker) while it is mounted on the control panel. Normally, there is continuity between each of the 2 terminals when the breaker is ON, while no continuity when the breaker is OFF. WY RGV12000 RGV13000T 8-4 STATOR Disengage connector[...]

8-5 ROTOR ASSEMBLY 1) Field coil Remove the brush holder and measure resistance between the slip rings. Rotor (Slip ring) Resistance RGV12000 4.11Q RGV1300dT 69.6 Q NOTE : If the circuit tester is not sufficiently accu- rate, it may not show the values given and may give erroneous readings. Erroneous reading will also occur when there is a wide var[...]

8-6 BRUSH The brushes must be smooth where they contact the slip rings. If not, polish smooth the brushes with sandpaper. A brush that is not smooth produces arcs between the brush and slip ring leading to possible damage. Usable brush lengths are from 5 mm to 15 mm (0.2 ” to 0.6”). A brush shorter than 5 mm must be replaced because decreased c[...]

8-8 CURRENT TRANSFORMER (RGV13000T only) Disconnect the connectors and coupiers of current transformer. Check the inter-terminal resistance of current transformer with a circuit tester. If current transformer is found to be faulty, replace with new one. 8-9 ECU (ELECTRONIC CONTROL UNIT) Check the resistance between 13 terminals of ECU with circuit [...]

8-10 IDLE CONTROL UNIT (RGV12000 only) Check the resistance between five terminals of IDLE CONTROL UNIT with circuit tester. Terminal number of the IDLE CONTROL UNIT Circuit tester (with battery power source 1.5 V) Apply black 0 needle of the circuit breaker needle of the cir- *Tester measuring range : 1000 k Q NOTE : The resistance readings vary d[...]

8-11 DIODE UNIT (RGV13000T only) Check the resistance between five wires of DIODE UNIT with circuit tester. Diode unit needle of the cir- cuit breaker 9. DISASSEMBLY AND ASSEMBLY 9-1 PREPARATION and PRECAUTIONS 1) Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly[...]

(1) Generator assembly STATOR Jw?i?M BUSHING 1 cFLANGE NUT ‘.j I 11.&13.7Nm 1 120-140Kg-cm 1 COVER ‘.I- MOUNT RUBBER Wk. =&‘! I END COVER RGV13000T onlv I -33-[...]

(2-l) Control Box (RGV12000) PLATE I I I‘ ’ CONNECTOR I I I / -._ EMOTE /’ EARTH / CONNECTOcd for RI CONTROL IDEL CONTROL SWITCH AC RECEPTACLE L NO-FUSE BREAKER -1 CiAMP e- /- AC RECEPTACLE STARTER SWITCH PRESSURE FINING LAMP I7 VOLi METER - 34-[...]

(2-2) Control Box (RGVI 3000T) PLATF CURRENT.TRANSFORMER EARTH (GROUND) I r ND-FUSE BREAKER VOLT METER AC dUTPUT TERMINAL -35-[...]

(3) Fuel Tank FILTER PACKING CUP FUELTANKw $j+ BRACKET STRAINER PURSE LOCK -36-[...]

a 1. FRONT COVER Attach the front cover to the engine main bearing cover. Match the faucet joint and tighten the bolts. I Tightening torque I 120-14Okg -cm 11.8-13.7 N .rn (8.7-10-l ft -Ibs) 2. ROTOR (1) Wipe off oil, grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft. (2) Mount the rotor to the engine[...]

4. REAR COVER (I) Attach the bushing over the lead wire drawn out from the rear cover. Press the smaller end of the bushing into the window of the rear cover. (2) Put the rear cover with stator and start cover over the rotor. Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover. (3) Fix the rear cover wi[...]

Attach the connetors to the brush holders. Connector the green wire to the stator end a and the brown wire to the bearing end. Install the brush cover. (5) (RGV13000T only) Attach the end cover to the rear cover. (6) Tighten the nuts over the mount rubber bolts to fix. I Tightening torque I 1 120-140kg -cm 11.8-13.7 N .rn (8.7-10.1 ft-lbs) NOTE : W[...]

IO. TROUBLESHOOTING 1 O-1 No AC output l Checking the exciting coil for resistance. (RGV12000) (Refer to 8-3.) If insulation is NG, replace exciting coil with new one. * Checking the brush and slip ring of rotor for resistance. (Refer to 8-3.) If insulation is NG, replace brush and slip ring with new one. * Check stator for winding resistance betwe[...]

10-4 Engine dose not run. Symptom Possible causes Remedy 1) The key switch (or remote switch) is turned to “START’ Wait for more than 2 seconds and then turn the within 2 seconds the engine has key switch to “START” position. been stopped. 1. Electric starter 2) The remote controller is con- Both the key switch of the generator and the dose[...]

11. WIRING DIAGRAM (RGV12000) mm)-;- JI I I I I I I , , 1 1 1 II f-5 III ,LEJ Connector (Remote control) GENERATOR CONTROL BOX AC output AC output AC output receptacle(l20V) receptxle(l~~Z40V) receptacle(l20/24OV) 1 4Gm Y : : i---.- Ik----L*----- ---__-_-------------- = 7; Exciting coil (Engine) : Red : White : Yellow BWR : BlecWRed FtiW : R&Wh[...]

a (RGVI 3000T) :ONTROL BOX -------_- ---------- -LGm 1 r-w---p-w1 wi C I $ -7 I I L to earth terminal Key switch ------------------- Iv- @ m&ssur GENERATOR CONTROL BOX __--------- , -__- ---_--_- ---- ----------- -- -1 AC output terminal 0 Earth(Ground) terminal -43-[...]

Robin America, Inc. 940 Uvely Blvd. l Wood Dale, It 60191 l Phone: 630-350-8200 l Fax: 630-350-8212 e-mail: sales@robinamerica.com l wwwrobinamerica.com 0 Copyright 2000 Robin America, inc. PRINTED IN THE USA[...]