Robin R1210 Brushless Service Manual

LE GENERATOR

210~

Section

CONTENTS

Page

10.

11.

12.

SPECIFICATIONS

..........................................................................

PERFORMANCE CURVES

...............................................................

2-1

AC Output

..............................................................................

2-2 DC Output ..............................................................................

FEATURES ..................................................................................

GENERAL DESCRIPTION OF THE GENERATOR

..................................

4-1

External View of Generator

...........................................................

4-2 Location of Serial Number and Specification Number ...............................

CONSTRUCTlON AND FUNCTION

.....................................................

5-1 Construction

...........................................................................

5-2 Function ................................................................................

5-3 Description of Generator Operation

................................................ 10

SAFETY PRECAUTIONS

................................................................

RANGE OF APPLICATIONS

............................................................

MEASURING PROCEDURES

.......................................................... 17

8-1 Measuring Instruments

...............................................................

8-2 AC Output Measuring

................................................................

8-3 DC Output Measuring

...............................................................

8-4 Measuring Insulation resistance

.....................................................

CHECKING FUNCTIONAL MEMBERS

...............................................

9-1

Control panel..

........................................................................

9-2 Stator ..................................................................................

9-3 Rotor ..................................................................................

9-4 Condenser

............................................................................

9-5 Diode Rectifier

........................................................................

DISASSEMBLY AND ASSEMBLY

....................................................

2 7

10-1

Preparation and Precautions

........................................................

10-2 Disassembly Procedures

.............................................................

10-3 Assembly procedures

................................................................

TROUBLE SHOOTING

..................................................................

11-1 No AC Output. .......................................................................

11-2

AC voltage is too high or too low

...................................................

WIRING DIAGRAM

......................................................................

RG-32

S E R \/I C E

NEWS

September-1995

Rk Generators

@ FUJI HEAVY INDUSTRIES LTD.

INDUSTRIAL PRODUCTS DIV.

MODEL

SUBJECT

R1210

Oil Sensor change

This Service News is to inform of the change of the oil sensor and wiring equipped with the ROBIN engine EY 15 for R1210 generator set.

1. Purpose To improve the performance of the oil sensor.

2. Main points of the modification

1) The oil level sensing mechanism of the oil sensor is changed from piezo-resonator type to potentiometer type.

2) The electric wiring and clamp are also changed.

3. Change of part number -

For the detail, refer to the attached figures.

New Parts set

NO. Part Name

Part number

1. Oil sensor CP.6

KS3-11015-01

+?k

Wire 7 CP.

227-73 107-O 1 1

3. Clamp

056-60002-50

Current parts set

NO.

Part name

Parl number

Q’tv

Oil level sensor CP.

227-76035-01

Wire 22 CP.

214-73122-01

Clamp CP.

206-75501-01

Interchangeability

It is interchangeable only when the all parts are replaced as a set; that is to say, the current parts set (item NO.4 to 6) can be replaced with new parts set (item NO. 1

to 3).

However, there is no interchangeability for the individual part.

4. Execution This oil sensor change is adopted to the new ROBIN generator set to be produced in

and after September 1995.

-1-

Attachment (A); oil sensor installation change

New installation

*:Clamping in detail

Current installation

Attachment (B)

1. Oil sensor change

New

OIL SENSOR CP 6

KS3-11015-01

Current

OIL LEVEL SENSOR CP

227-76035-01

-3-

2. Electric wiring change New

wIRE7CP. 227-73107-01

Current wm

22 cP .

214-73122-01

3. Clamp change New

CLAMP

056-60002-50

d 6.5

Current

CLAMP CP.

206-75501-01

3 I

J--

-3

Section A-A

-4-

1. SPECIFICATIONS

Generator

Type

Frequency

AC Voltage

(Rated current)

Bushless, self-exciting, 2-pole, single phase, revolving field

50 Hz

60 Hz

11 OV (7.3 A)

11OV (9.1 A)

220V (3.6 A)

12OV (8.3 A) 230V (3.5 A) 220V (4.5 A) 240V (3.3 A)

Engine

/ AC Output

Max. 1000 w

1200 w

Rated :

800 W

1000 w

/ DC Output

12V-8.3A(lOOW)

Voltage regulation system

Condenser system

Type

Forced air-cooled, 4-stroke, side valve,

’ gasoline engine

Displacement

, 143 cc (6.73 cu. in)

Bore x Stroke

63 x 46 mm (2.48 x 1.81 in)

I Fuel

I Automotive gasoline

! Fuel tank capacity

3.5 liters (0.9 U.S. gal)

Oil pan capacity

600 cc (1.3 U.S. pints)

Rated continuous operating hours

Dimensions (L X W X H)

Dry weight

486 x 288 x 410 mm

; (19.1 x 11.3 X 16.1 in.)

27.5 kg (60.6 Ibs.)

-5-

2-1

PERFORMANCE CURVES

AC OUTPUT

>^ 240 E

9 5 220

800

9 200

600 $

F i?

2 A 55

5 400

0 5

6 50 3

s E 45 200

1, I t I I

0 0 1

2 3 4 5

CURRENT(A)

oI;i

600 =g

i= z

400

200

Output Max.

...................... 1 (-J)()w

Rated ..................... 8OOW

Frequency ........................ 50Hz

Voltage

...........................

220v

Output Max.

......................

12o()w

Rated

....................

,oooW

Frequency

........................

60~~

Voltage

...........................

12ov

CURRENT(A)

-2-

DC OUTPUT

m voltage

.........................

,2v

DC Ampere

......................... 8.3A

DC output

.........................

,()ow

The voltage curve shown in the left indicates the characteristic of DC output when charging a battery. The voltage may be decreased by 20% when the resistance load is applied.

0 2

4 6

8 10

CURRENT (A)

-3-

3. FEATURES

3-l BRUSHLESS ALTERNATOR

New brushless alternator has put an end to costly brush maintenance and down time.

3-2 CONDENSER VOLTAGE REGULATOR

Condenser voltage regulation ensures stable voltage output under all working conditions.

3-3 COMPACT, LIGHTWEIGHT, CARRYING EASE

As the new burshless alternator makes the Robin R1210 lightest in the class at 27.5 kgs, you can

easily carry it around using the convenient carrying handle.

34 EASY OPERATION

One-touch engine control switch integrates engine on/off switch and choke lever. All controls are conveniently concentrated on the front panel.

3-5 LONG CONTINUOUS OPERATION

The large 3.5 liters fuel tank allows four hours of operation at 50Hz rated output.

3-5 MINIMAL MAINTENANCE

Brushless alternator eliminates time consuming brush maintenance.

Trouble-free condenser voltage regulation for greater dependability.

No-fuse resettable circuit breakers.

0 Electronic pointless ignition system for sure starts.

3-7 LONG LIFE DURABILITY

Tough, heavy-duty Robin EY15 engine incorporates a cast iron cylinder liner, forged steel crankshaft and two main ball bearings for longer service life.

0 The brushless alternator dose not have any expendable parts such as brushes and slip rings or

fragile circuit board assuring trouble-free operation for longer service life.

-4-

4. GENERAL DESCRIPTION OF THE GENERATOR

4-1 EXTERNAL VIEW of GENERATOR

DC Circuit Breaker

Engine Control Switch (CHOKE-RUN-STOP)

AC Receptacle

Ground Terminal

Air Cleaner Cover

Spark Plug

Cover

Fuel

Tank

Drain Plug

Oil Filler Cap

-5-

Carrying Handle

- Fuel Tank Cap

4-2 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER

Serial number and specification number are stamped on the LABEL(MODEL NAME)stuck on the rear cover.

NOTE: Always specify these numbers when inquiring about the generator or ordering spare parts in

order to get correct parts and accurate service.

LABEL

(SPEC.)

[Example]

LABEL

(MODEL

PROD. NO. RGOl2216010-*

Specification No.

1234 -

SER. NO.

1000001 1

Production No.

Serial No.

-6-

5. CONSTRUCTION AND FUNCTION

5-1 CONSTRUCTION

ROTOR COMPLETE

END COVER

tip Co”PLER y- REAR YOVER

\ STATOR COMPLETE

BALL BLARING

’ ,

DlODi RECTIFIER :

STATOR COVER

;

CONDiNSER

MOUNT

&BBER

THROtiGH BOLT

FRONT ~&OVER

Fig. 5-7

5-2 FUNCTION

5-2-i 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.

Fig. 5-2

-7-

5-2-2 CONDENSER A

condenser is mounted on the rear cover and is connected to the condenser coil which is wound on the stator. This condenser and condenser coil regulate the output voltage.

5-2-3 ROTOR

The rotor consists of a laminated silicon steel sheet core and 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 cooling fan is pressure-fitted on the end of the

rotor shaft to cool the coils, cores, rectifier, and other generator parts. (See Fig. 5-4)

A diode rectifier and resister are mounted inside of

the insulator. (See Fig. 5-5)

Cooling air is sucked by the rotor fan through the slits of the rear cover and is expelled through the outlets of the front cover.

Fig. 5-3

Fig. 5-4

DE RECTIFIER

Fig. 5-5

-8-

5-2-4 CONTROL PANEL

The control panel has a double AC receptacle with a ground terminal, and a DC receptacle. The voltmeter displays output voltage of the generator. The circuit breaker for AC and DC in the upper section of the control panel protects the generator from getting damages caused by overloading or defective appliance.

Fig. 5-6

-9-

5-3 DESCRIPTION of GENERATOR OPERATION

INITIAL EXCITATION INITIAL EXCITATION

STATOR STATOR

PERMANENT MAGNETO PERMANENT MAGNETO

FIELD COIL

ROTOR ROTOR

7 ----_---It

RESISTOR or RESISTOR or

---

DIODE DIODE

MAIN COIL

CONDENSER COIL

Fig. 5-7

5-3-l GENERATION 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 in the main coil and 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 @ 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 magnetic 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 voltages 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 magnetizes the rotor core to generate an output voltage in the main coil.

(4) When generator speed reaches 2700 to 2800 rpm (50Hz type) or 3000 to 3300 rpm (60Hz 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.

5-3-2 VOLTAGE FLUCTUATIONS UNDER LOAD

When the output current g flows through the main coil to the appliance, a magnetic flus is produced and

serves to increase current 3 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.

- 10-

5-3-3 DC OUTPUT

DC output is taken out from the DC coil and is fed to the diode stack (rectifier) where the output undergoes full-wave rectification and is then supplied to the load. The diode works to allow the current to flow in the direction 83, but does not allow the current to flow in the direction 8, as shown in Fig. 5-8-l.

Fig. 5-8-7

Fig. 5-8-2 shows the DC output circuit of the

generator. DC voltage is generated in the DC coil. When the voltage in A is higher than that in 6, the current @ flows in the direction shown in the

figure, while no current flows between CF and

because the current is cut off by the diodes G4 and

G2. On the contrary, when the voltage in B is higher than that in

the current (2 flows in the

direction as shown in the figure. No current flows between

and

because the current is cut off

by the diodes

and G3.

Fig. 5-8-2

As a result, the voltage generated at the output terminal has a wave form with two peaks in one cycle, as in the case of the output wave form shown in Fig. 5-B-3.

Output Waveform

Fig. 5-8-3

CAUTION : Do not use DC and AC output simultaneously.

Due to a characteristic of the condenser voltage regulation, simultaneous use of DC and AC output creates voltage drop in DC output resulting in incapability for charging batteries.

- 11 -

+ 38 hidden pages

Robin R1210 Brushless Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual