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SERVICE
MANUAL
Models
RGV2800, RGV4100,
RGV6100
Generators
PUB-GS1277
Rev. 1/04
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CONTENTS Section Title Page 1. SPECIFICATIONS ....................................................................................................... 1 2. PERFOMANCE CURVES ........................................................................................... 3 3. FEATURES.........................................................................................................
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Section Title Page 9-4 STATOR .............................................................................................................. 33 9-5 ROTOR ASSEMBLY ........................................................................................... 34 9-6 CONDENSER ..................................................................................................... 34 9-7 DI
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1. SPECIFICATIONS - 1 - M0 odel R0 GV280 RGV410 Type Brushless, Self Exciting, 2-Pole, Single Phase Frequency 60 Hz MW aximum Output2W 800 4100 ACRW ated Output 2W 300 3600 1A 20V 1V 9.2 1A 20 30.0 Rated Voltage Current 1A 20V/240V1V 9.2A/9.6 1A 20V/240 30.0A/15.0 Power Factor 1.0 DC Output 12 V-8.3 A (100 W) Voltage Regulator Condenser Type Type Air-Cooled 4-Cycle, Overhead Valve Gasoline Engine MD odel ED H17-2 EH25-2 3 3 Dm isplacement 172 c(m 10.50 cu. in.) 251 c (15.32 cu. in.) Rm ated Outp
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- 2 - M0 odel RGV610 Type Brushless, Self Exciting, 2-Pole, Single Phase Fz requency 60 H MW aximum Output 5800 AC RW ated Output 4800 Rated Voltage 1A 20V/240V 40A/20 Current P0 ower Factor 1. D) C Output 12 V-8.3 A (100 W Ve oltage Regulator Condenser Typ Type Air-Cooled 4-Cycle, Overhead Valve Gasoline Engine MD odel EH34 3 Dm isplacement 338 c (20.63 cu. in.) Rm ated Output 8.0 HP / 3600 rp Fe uel Automobile Gasolin F) uel Tank Capacity 5.67 U.S. gal. (21.5 liters Rated Coutinuous Operation
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2. PERFOMANCE CURVES ( ) Hz 63 Hz 62 61 60 ( ) V 250 ( ) 125 240 230V/115V ( ) 120 230 ( ) 115 220 ( ) 110 0 1/2 4/4 Load Rated - 3 -
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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. - 4 -
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3. FEATURES 3-1 BRUSHLESS ALTERNATOR Newly developed brushless alternator eliminates troublesome brush maintenance. 3-2 CONDENSER TYPE VOLTAGE REGULATOR A trouble free condenser type voltage regulator ensures a stable voltage under all working conditions. 3-3 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. 3-4 QUIET OPERATION Robin RGV series generator delivers a quiet operation with : * A large
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3-9 MINIMAL MAINTENANCE * A brushless alternator release the operator from periodical brush maintenance. * A trouble free condenser type voltage regulator. * A drip-proof alternator design. * No-fuse circuit breakers. * An electronic pointless ignition system. * A dust-proof cyclone air cleaner. 3-10 LONG-LIFE DURABILITY The heavy-duty 4 stroke Robin Rro OHV engine and virtually maintenance-free brushless alternator ensure greater durability with : * A brushless alternator with a condenser volta
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4. GENERAL DESCRIPTION 4-1 EXTERNAL VIEW FUEL GAUGE TANK CAP VOLTMETER ENGINE SWITCH FULL POWER SWITCH CHOKE KNOB AC RECEPTACLE AIR CLEANER EARTH TERMINAL DC OUTPUT TERMINAL RECOIL STARTER IDEL CONTROL SWITCH DC CIRCUIT BREAKER NO-FUSE OIL SENSOR BREAKER SPARK PLUG ENGINE EMISSION LABEL MUFFLER OIL DRAIN PLUG OILGAUGE (OIL FILLER) - 7 -
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TEST RESET 4-2 CONTROL PANEL * RGV2800 : U.S.A., 60Hz-120V [NEMA RECEPTACLE] AC OUTPUT V METER ENGINE SWITCH ON AC MAX 20A ON OFF DC 12V-8.3A OFF BATTERY CHARGE ONLY DC OUTPUT DC BREAKER AC BREAKER * RGV4100 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE] AC 120V FULL POWER SWITCH AC 120V / 240V V METER ENGINE SWITCH 120V ON 120V 240V OFF RESET TEST IDEL CONTROL ON 30A ON 20A 125V AC MAX 20A AC MAX 30A AC MAX 20A OFF ON OFF OFF DC 12V-8.3A BATTERY CHARGE ONLY DC OUTPUT DC BREAKER AC BREAKER - 8 -
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* RGV6100 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE] AC 120V FULL POWER SWITCH AC 120V / 240V V METER ENGINE SWITCH 120V 120V /240V ON RESET OFF TEST 30A 20A 150V ON IDEL CONTROL AC MAX 30A AC MAX 20A AC MAX 20A ON OFF ON OFF DC 12V-8.3A BATTERY CHARGE ONLY OFF DC OUTPUT DC BREAKER AC BREAKER 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 control box. NOTE : Always specify these
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5. CONSTRUCTION AND FUNCTION 5-1 CONSTRUCTION END COVER BALL BEARING STATOR COMPLETE ROTOR COMPLETE REAR COVER STATOR COVER CRANKSHAFT MOUNT RUBBER THROUGH BOLT COVER BOLT FRONT COVER Fig. 5-1 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. Fig. 5-2 - 10 -
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5-2-2 CONDENSER One or two condensers are installed in the con- trol box and are connected to the condenser coil of the stator. These condensers and condenser coil regulate the output voltage. Fig. 5-3 5-2-3 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. Fig. 5-4 A diode rectifier and surge absorber is m
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5-2-4 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. MN ODELSR PECIFICATIONN O-FUSE BREAKE OBJECT or PROTECTIO RGV28006A 0 Hz-120V 2e 0 Total output amperag RGV41006) 0 Hz-120 V/ 240V1e 5 A (2-Pole, 2-Element Total output amperag 2e 0 A (2-Pole, 2-Element) Total output amperag RGV6100 60 Hz-120 V/ 240V 3e 0 A Output from 3
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Se tyle Ae mperRg eceptaclAn C plu Descriptio GFCI (Ground Fault Circuit Interrupter) uA p to 20ANP EMA 5-20 NEMA 5-20 Receptacle, duplex (REC1) Locking Receptacle uR p to 20ANP EMA L14-20 NEMA L14-20 (REC2) Locking Receptacle uR p to 30ANP EMA L5-30 NEMA L5-30 (REC3) Table. 5-2 NOTE : If your generator has receptacles pecu- liar to your country, Table 5-2 does not apply. TWIST Caution : The duplex 120V receptacle is protected by a GFCI (Ground Fault Circuit Interrupter). GFCI shuts off the outp
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5-2-8 CONNECTING TO DOMESTIC CIRCUITS (HOUSE WIRING) WARNING : 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 power source during power outage, all connections must be made by a licensed electrician. Failure 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 wiri
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Utility high line House circuit breaker Meter box XW Y 120V appliance 240V appliance 120V X WY appliance Transfer switch Generator ( ) W ()( ) X Y ( ) G 240V 4P- Receptacle Fig. 5-10 (c) Operating the generator. Set the full power switch to 120V/ 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
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5-3 GENERATOR OPERATION Fig. 5-11 5-3-1 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 a which flows through the condenser coil. At this time, a small flux is produced with which the magnetic force at the rotor’s
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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. Fig. 5-12 Fig. 5-13 Switch LOWER VOLTAGE HIGHER VOLTAGE Position RECEPTACLE RECEPTACLE 1t 20/240 VHt alf of rated outpu Rated outpu Table. 5-3 Fig. 5-14 - 17 -
