Subaru Robin Power Products RGV7500 User Manual

SERVICE

MANUAL

Model

RGV7500

PlJB-GS1436

Rev.

05/00

Section

Title

Page

l.'SPECIFICATIONS

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

1

2

.

PERFOMANCE CURVES

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

2

3

.

FEATURES

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

3

3-1 A.V.R. ALTERNATOR

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

3

3-2 OIL SENSOR

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

3

3-3

QUIET

OPERATION

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

3

3-4

NO

RADIO

NOISE

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

3

3-5 LARGE FUELTANK

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

3

3-6 RUGGED TUBULAR FRAME

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

3

3-7

COMPACT AND LIGHT WEIGHT

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

3

3-8 MINIMAL MAINTENANCE

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

3

3-9 LONG-LIFE DURABILITY

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

4

.

GENERAL DESCRIPTION

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

5

4-1 EXTERNAL VIEW

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

5

4-2 CONTROL PANEL

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

6

4-3 LOCATION

of

SERIAL NUMBER

and

SPECIFICATION NUMBER

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

6

5 .

CONSTRUCTION AND FUNCTION

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

7

5-1 CONSTRUCTION

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

7

5-2 FUNCTION

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

7

5-3

GENERATOR OPERATION

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

13

5-4 OIL SENSOR

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

16

6 .

SAFETY PRECAUTIONS

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

19

7

.

RANGE

OF

APPLICATIONS

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

20

8

.

MEASURING PROCEDURES

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

23

8-1 MEASURING INSTRUMENTS

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

23

8-2 AC OUTPUT MEASURING

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

26

8-3

DC OUTPUT MEASURING

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

26

8-4 MEASURING INSULATION RESISTANCE

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

27

9

.

CHECKMG

FUNCTIONAL MEMBERS

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

29

9-1 VOLfMtrER

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

29

9-2

AC RECEPTACLES

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

29

9-3 No-FUSE BREAKER

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

29

Sectior! Title . Page

9-4

STATOR

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

30

9-5

ROTOR ASSEMBLY

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

30

9-6 BRUSH

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

31

9-7 A.V.R. (AUTOMATIC VOLTAGE REGULATOR)

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

31

9-8

IDLE CONTROL UNIT

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

33

9-9

DIODE RECTIFIER

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

34

9-1 0 OIL SENSOR

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

35

9-11 EXCITING COIL

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

35

1O.DISASSEMBLY AND ASSEMBLY

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

36

10-1 PREPARATION

and

PRECAUTIONS

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

36

10-2 DISASSEMBLY PROCEDURES

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

37

10-3

ASSEMBLY PROCEDURES

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

..

45

10-4 CHECKING, DISASSEMBLY

and

REASSEMBLY

of

the

FRONT PANEL

........

50

11

.

TROUBLESHOOTING

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

52

11-1

NO AC OUTPUT

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

52

11-2 AC VOLTAGE

IS

TOO HIGH OR

TOO

LOW

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

53

\

11 -3 AC VOLTAGE

IS

NORMAL AT NO.LOAD.

I

BUT THE LOAD CANNOT

BE

APPLIED

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

54

11

-4

NO

DC OUTPUT

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

55

11-5

IDLE CONTROL(OPTI0NAL EQUIPMENT)

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

56

12

.

WIRING

DIAGRAM

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

59

NOTE

:

As

for the servicing information

on

engine protion. please refer to the

EH41

engine

sewice

manual

.

1.

SPECIFICATIONS

Model

RGV7500

j:

U

Brush, Self Exciting, 2-Pole, Single Phase

60

Hz

~~ ~ ~ ~

Maximum Output

6000

W

Rated Output

7300

W

Rated Current

Voltage

120V1240V

50N25A

Power

Factor

1

.o

I

DC Output

12 V-8.3

A

(1

00

W)

I

Voltage Regulator

I

AVR Type

I

Air-Cooled 4-Cycle, Overhead Valve Gasoline Engine

I

Model

EH41

D

I

Displacement

404 cm3 (24.63 cu. in.)

I

Rated Output

9.5

HP

I

3600

rpm

I

Fuel

Automobile Gasoline

I

Fuel Tank Capacity 7.26

U.S.

gal. (27.5 liters)

Rated

Coutinuous

Operation

I

Approx. 7.0 hours

I

Oil Capacrty

0.32

US.

gal. (1.2 liters)

Starting System

I

Recoil Starter and Optional Electric Starter

I

Dimensions

(L

x W

x

H)

*

Electric

starter motor is available asoption.

198.4 Ibs. (209.4 Ibs.)' 190 kg (95 kg)*

Dry Weight

27.2

x

20.9 x 20.9 in.

(690

x

530

x 530 mm)

-

1-

2. PERFOMANCE CURVES

RGV7500

/

60

Hz

(6.0

kVN240V)

Load

Rated

DC

OUTPUT

DC Voltage

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

12

V

DC Ampere

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

8.3

A

DC output

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

100

W

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.

NOTE

:

It is possible to use both

DC

and

AC

outputs simultaneously up to the rated output

in

total.

f

\

-

2-

3.

FEATURES

3-1

AVR ALTERNATOR

Output votage becomes more stable due to

AVR

system.

3-2

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.

3-3

QUIET OPERATION

Robin RGV series generator delivers a quiet operation with

:

A

quiet 4-stroke Robin Rro

OHV

engine.

Extra large muffler and large air cleaner provide remakable quiet operation.

3-4

NO RADIO NOISE

Noise suppressor spark plug is equipped standard to prevent radio frequency interference.

3-5

LARGE FUEL TANK

The large fuel tank

(27.5

L)

allows more than 7 hours of continuous operation which is sufficient for a half

day or one day

work

without refueling.

3-6

RUGGED TUBULAR FRAME

Full cradle type rugged tubuler frame protects the generator all around.

3-7

COMPACT

AND

LIGHT WEIGHT

".

Newly developed brushless alternator enabled the RGV generators to be very compact in size and light in weight.

3-8

MINIMAL MAINTENANCE

A

drip-proof alternator design.

No-fuse circuit breakers.

An

electronic pointless ignition system.

-

3-

3-9

LONG-LIFE DURABILITY

The

heavy-duty

4

stroke

Robin

OHV

engine

:

*

Full rubber mount in a sturdy tubular

frame.

*

A

forged

steel

crankshaft supported by

two

main ball bearings.

A

pointless electronic ignition system.

*

A

cast-iron cylinder liner.

I

\

-

4-

4.

GENERAL

DESCRIPTION

4-1

EXTERNAL

VIEW

FUEL GAUGE

CONTROL

PANEL

AIR

CLEANER

RECOIL STARTER

IL GAUGE (OIL FILLER)

OIL DRAIN PLUG OIL

SENSOR

FUEL TANK

CHOKE LEVER

SPARK PLUG

CAP

OUTLET

-

5-

4-2

CONTROL PANEL

HOUR

METER VOLTMETER PILOT

LAMP

:\.ET3i

STARTER TYPE)

\

:;FEY

AKCLE

\

I

’

NO-FUSE BREAKER IDEL CONTROL

DC

OUTPUT

SWITCH TERMINAL

I

ENGINE SWITCH

DC

CIRCUIT

BREAKER

(RECOIL STARTER TYPE)

4-3

LOCATION

of

SERIAL

NUMBER

and

SPECIFICATION NUMBER

Serial

number

and specification

number

are stamped on

the

LABEL

(MODEL

NAME)

stuck on the

side

wall

of rear cover.

I

NOTE

:

Always specify these numbers when inquiring about the generator or ordering spare

parts

in

order to get correct parts and accurate service.

LABEL,

MODEL

NAME

-

6-

5. CONSTRUCTION AND FUNCTION

5-1

CONSTRUCTION

STATOR. COMPLETE

MOUNT RUBBER BALL BEARING

TROUGH

BOLT FRONT COVER

Fig.

51

5-2

FUNCTION

5-2-1

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.

3

Fig.

5-2

-

7-

5-2-2

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.

Slip

rings

are

provided

on the rotor shaft to

re-

ceive

DC

exciting current from

A.V.R..

5-2-3

BRUSW

BRUSH

HOLDER

An

exciting current

is

supplied

from

the

A.V.R

to

the rotor. The brushes are made

of

carbon and

the

brush-holder of plastic.

It

is

necessary to

keep

the

contact

pressure

be-

tween

the brushes

and

slip

rings

withing

specific

limits.

Thus,

care

must

be taken of

brush

length.

Fig.

5-3

5-2-4

A.V.R. (AUTOMATIC VOLTAGE REGULATOR)

The

automatic voltage regulator employs an elec-

tronic circuit

to

automatically regulate voltage.

Fig.

5-5

~

Fig.

5-4

-

a-

5-2-5

IDLE

CONTROL

UNIT

The idle control unit releases throttle valve when

the applied load current exceeds

0'.04A.

The

two

output wires from the main coils must go

through the

ZCT

in the same direction.

NOTE

:

It

is

normal that the engine speed goes up for

a

moment when you turn the key switch to

"STOP"

while the Auto Idle Switch

is

in

"ON"

position.

I

Fig.

5-6

5-2-6

NO-FUSE

BREAKER

The no-fuse breaker protects the generator

from

getting damage

by

overloading

or

short circuit in the

appliance. Table

5-1

shows the capacity of no-fuse breaker

by

each spec. and their object of protection.

I

SPECIFICATION

OBJECT

of

PROTECTION

NO-FUSE BREAKER

60

HZ-

120

V/

240V

'

Total

output

amperage

25 A (2-Pole, 2-Element)

Table.

5-1

5-2-7

DC

CIRCUIT

BREAKER

The

10

ampere

DC

circuit breaker mounted on

the control panel protects whole

DC

circuit from

getting damage by overload or short circuit.

Fig.

5-7

-

9-

Table.

5-2

Caution

:

The duplex

120V

receptacle

is

protected

by

a

GFCl

(Ground Fault Circuit Interrupter).

GFCl shuts

off

the output current from the

duplex

120V

receptacle when a ground fault

occurs

in

the generator or the appliance.

Please note that other receptacles are

not

pro-

tected

by

GFCI.

1

\

TWIST

1

Caution

:

To

connect the appliance to locking

receptacle, insert the

plug

into the

re-

ceptacle and

turn

it

clockwise to lock.

-

10-

5-2-9

GFCI

RECEPTACLE

After starting the engine, check the

GFCI

for'proper functioning by the following test procedure.

Push blue TEST button, The red

RESET

button

will

pop out exposing the word TRIP. Power is now

off

at

the outlets protected by the GFCI, indicating that the device is functioning properly.

If

TRIP

dose not appear when testing,

do

not

use

the generator. Call a qualified electrician.

To

restore power, push

RESET

button.

WARNING

:

If

the

RESET

button pops out during operation, stop the generator immediately and

call

a

qualified electrician for checking generator and the appliances.

5-2-10

CONNECTING

TO

DOMESTIC CIRCUITS

(HOUSE

WIRING)

Fig.

5-9

WARNING

:

This generator

is

a neutral grounded

type.

ff

a

generator

is

to

be connected to residential or commercial power lines, such as a stand-by

Faitwe

in

connection may result in death, personal injury, damage to generator, damage to appli-

ances, damage to the building's wiring or fire.

(a)

When

contnecting a Robin generator to a house wiring, generator output power must be taken from

.

power

source

during power outage,

all

connections must be made by a licensed electrician.

the

240V-4P

receptacle.

-

11

-

Utility

high line

House circuit

breaker

-

v

I

120v

appliance

I

120v

appliance

-

240V

I

,A-

appliance

I

"

-

I

"""""""""""""""""

=

4P-

Receptacle

Fjg.

5-

70

(b) Install a transfer switch.

i

I

A

transfer switch must be installed to transfer the load from the commercial power source to the

1

generator. This switch is necessary

to

prevent accidents

caused

by the recovery from power outage.

'

Use a transfer switch of the correct capacity. Install transfer switch between the meter and the fuse or

AC

breaker box.

Caution

:

If

the neutral wire of house wiring is grounded,

be

sure to ground the ground terminal

of

the

generator. Otherwise an electric shock may occur to the operator.

(c) Operating the generator.

Set the full power switch to

120W

240V

side.

Turn the house AC breaker

off

before starting the generator.

Start the generator and warm

it

up.

Turn the house AC breaker on.

Caution

:

Do

not start the generator

with

electrical appliance

(s)

connected and with their switches on.

Otherwise the appliance

(s)

may be damaged by the surge voltage at starting.

i

-

12

-

53

DESCRIPTION

Of

GENERATOR

OPERATION

5-3-1

PRIMARY

EXCITING

ACTION

When the generator is started, the permanent

magnet on the engine rotates to generator a voltage in the exciting coil. This voltage is regulated by

a

diode in the A.V.R. to feed a current to the

generator field coil. (FC). (See Fig.

5-11)

The rotor is turned an electromagnet by that current and rotates

so

that voltage are generated in the stator coils (main coil and sub coil). The voltage generated in the sub coils is operated

by

the A.V.R. to feed a current to increase the field coil current. (See Fig.

5-12)

As a result, the rotor magnetism increases. This operation is repeated to generate the rated

voltage at

60

Hz

in the main coil and

DC

coil.

5-3-2

VOLTAGE REGULATING MECHANISM

Connect a load to the AC output terminal and increase current. Output voltage varies as shown

in Fig.

5-13

depending on whether an automatic

voltage regulator is used or not. The operation

of

the A.V.R. is explained below.

When an AC output is taken, the engine is loaded and its rpm falls, Also the AC voltage fails due to the voltage drop caused by the internal resistance of the coils. The

A.V.R.

detects this voltage drop and its built-in SCR automatically increase the current flows to the field coil. As a result, the rotor magnetism increase, the voltage fallen by the load current is raised: and the output voltage is kept constant. If the AC output

is

reduced, the SCR operates in the opposite way to similarly keep the output voltage constant.co,ndenser coil. When current a increases, the density of magnetic flux across the rotor core rises. As a result, the current flowing

in

the field

coil

increases and the gen-

erator

output

voltage

is

prevented from decreas-

ing.

FC

n

EC

i

L""""""-J

ENGINE

MAGNETO

Fig.

5-

11

Fig.

5-12

WITHOUT AVR

RATED VOLTAGE

v

I

4A

Fig.

5-

13

-

13-

5-3-3

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

receptacle

in

each voltage.

120/240v

r---

1

MC1

240v

1

-

t.-

Fig.

5-

14

MC1

MC2

Fig.

5-

15

MC1

MC2

1

Fig.

5-

15

-

1

REC.~

r

Switch

RECEPTACLE RECEPTACLE

Position

HIGHER VOLTAGE

LOWER VOLTAGE

MC1

1

RECB

Rated output

Half

of

rated output

120/240

V

Table.

5-3

-

MC2

I

-

Fig.

5-

16

-

14-

Two main coils are wound over stator core. Each main coil outputs half the rated power at the lower

voltage (120V). 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. 5-14 shows a circuit diagram. When the full power switch is set for single lower voltage indication (120V), the switch position is as indicated by the lower solid line in the diagram. Fig.

5-1

5

is a simplified

representation of this circuit, showing the

two

main coils connected in parallel. In this case, the higher

voltage

(240V)

at Rec. 3 cannot be taken out. Rec. 2 for the lower voltage can output

up

to the rated

power (up to

30A

if

the rated current is over

30A),

and Rec. 1 can output up to a total of 15A.

When the full power switch is set for double voltage indication (120V/240V), the switch position is as

indicated by the upper dotted line in Fig. 5-1

4.

Fig.

5-1

6

is a simplified representation of this circuit,

showing the

two

main coils connected in series. In 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

5-4

is a summary

of

the above explanation. Select.the proper output voltage by full power switch in

'

accordance with the appliance to be used.

-

15-

5-4

OIL

SENSOR

541

DESCRIPTION

The

oil

sensor mainly functions

to

detect posi-

tion

of

the

surface of

engine

oil

in

the crankcase

of engines

for

general

use

and

to stop

the

en-

gine automatically

when

the

oil level goes

down

below

the

lower

limit

specified.

This

prevents

sei-

zure

of

engine from occurring

due

to insufficient

amount of oil

in

the crankcase.

Since

the

sensor

has

been

designed

to.consume

a part

of

power supplied to the igniter

to

ener-

gize

its

electronics circuit, any other external

power

supply

is

not

necessary

so

that

it

can

be

mounted at the oil

filler

port.

OIL

SENSOR

Fig.

5-

17

Introduction

of

newly

developed

sensing

principle features

super

durability and no change

with

the

passage

of

time

as

it

does

not

use

any

moving part.

Merits

due

to introduction of electrical conductivity detection are

as

follows

;

@

It

has resistance

to

mechanical shocks

and

property

of

no

change

with

the passage

of

time as

@

At

the

same time,

it

is

capable of detecting the

oil

level

stably

as

it

is

not influenced

by

engine

@

No

error occurs due to foam and

flow

of the oil.

@I

Influence against

the

ignition

system

or

the

electronics

units

can

be neglected because an electric

sensing

element

consists

simply

of electrodes having no moving parts.

vibrations.

current

supplied

to

the

sensor can be decreased.

5-4-2

PRINCIPLE

OF

SENSING OIL LEVEL

There

is

a great

difference

between electric resistance

of

air

and

that

of

oil. Since the resistance

of

air

is

far higher than that of oil, more electric current passes through

the

oil

than

through

the

air, although

absolute value of the current

is

very

small.

The

sensor

detects

this

current difference and

make

use

of

it.

The

sensor

judges

the oil quantity,

by

comparing a current flowing across a pair of electrodes (inner

and

outer)

with

the

reference,

in

such

a way

that

if

a

current

flows

between the electrodes

more

than the

reference, sufficient oil

is

in

the

crankcase, on

the

other

hand,

if

a

current flows

less

than

the

reference,

oil

is

not sufficient. Since an electric current

is

flown

to

detect

oil

quantity,

this

is

called the “electrical

conductivity detection” type of sensor.

The

oil

level

to

be detected

is

determined

by

the length

of

elec-

trodes

and

their mounting positions

with

the engine.

5-4-3

HOW

IT

OPERATES

[Power

supply]

The sensor makes use

of

a part of primary power source

for

ignition

of

the engine

(igniter)

to

drive

the

sensor

circuit. Power to

the

sensor

can

usually

be

derived

from

the

“stop button”

by

branching

wires

out.

-

16-

[Judgement

of

oil

level]

When sufficient oil is in the crankcase, both of inner and outer electrodes are immersed in the oil through which current flows across the electrodes. The sensor judges that oil in the crankcase is sufficient. When

oil level goes down and the inner electrode is exposed to the air due to consumption of oil, no current flow between the electrodes as air is considered to be electrically nonconductive. The sensor in this case

judges that oil is insufficient.

[Decision

of

oil

shortage]

.Oil level at the electrodes may go down momentarily probably due to the engine being slanted or affected

by vibration even

if

a sufficient oil is in the crankcase. For that reason, the sensor has an electronic timer

circuit to prevent it from interpreting as short

of

oil

when amount of oil is sufficient. The sensor has been

designed

so

that the engine is to be stopped only when oil-shortage is detected for 5 seconds uninter-

rupted. The timer employs an integration circuit and

it

is to be reset when the inner electrode

is

soaked in

the oil again before the sensor decides it as oil-shortage. The oil level where the sensor decides as oil-

shortage, when oil level goes down gradually, is called "threshold level".

[Automatic

stop

of

engine]

When the sensor decides as oil-shortage, it makes the engine to stop running automatically for protection

of

engine. Once the stopping circuit is activated, it keeps functioning until it confirms that the engine

has made a complete stop, then the circuit stops functioning automatically.

5-4-4 BLOCK

DIAGRAM

OF

THE

CIRCUIT

Power circuit

igniter

Inner pole

-

Detection

-

circuit

'

Deley

circuit

Stopping

oil

1

+

-Pole

Engine ground

Fig.

5-18

0

Power

circuit

..........

This rectifies a part of power to the igniter and regulates it

to

supply the st&+

lized power

to

necessary circuits.

-

17-

@

Detection circuit

.....

This detects quantity of

oil,

sufficient or not, according to difference of electric

resistance across inner and outer electrodes.

@

Delay circuit

...........

This his prevents the sensor from making an unnecessary stop of the engine

by momentary lowering of the oil level due to the engine being slanted or

affected by vibration in spite of sufficient oil in the crankcase.

@I

Stopping circuit

......

This automatically stops the engine running.

5-4-5

CAUTIONS TO

BE

TAKEN ON HANDLING THE SENSOR

(1)

Oil sensor unit

0

Be sure not to damage each

wire.

Broken or short-circuited power supply wires and/or a ground-

ing wire in particular may lead to malfunction or breakdown.

@

The sensor is not interchangeable from engine to engine because the sensor is to be exclusively

installed individually in each engine employed.

(2)

Mounting and wiring of oil sensor unit

0

Although this has been designed to have enough antinoise properties in practical use,

do

not

route the sensor wirings in the vicinity of noise-generating sources such

as

ignition plugs or high

I

voltage

cords.

This may cause malfunction or breakdown.

@

Since capacity of power source is limited, current flown in the electronic circuit

of

the sensor is

kept as low as possible. Be sure

to

use terminals with a high contact reliability of more than that

of

tinned terminals.

\

(3)

Operation of oil sensor

@

If

operating with the engine kept tilted, oil surface inside of the engine varies and the correct oil

~

level can not to be detected which in turn obstructs the preventing function

of

engine seizure.

I

Operate the engine by keeping

it

level.

@

When starting the engine with an insufficient oil in the crankcase, engine starts once then

it

stops

j

automatically after it runs for

5

seconds.

i

@

When the engine has been stopped by the oil sensor, voltage remained in the electronic circuit prevents the sensor from being restarted for

3

seconds after the engine stop. Try to restart the

~

engine after 3 seconds or more.

I

i

-

18-