TROUBLE SHOOTING MANUAL

Transcription

1 TROUBLE SHOOTNG MANUAL Mode RGDGOOT 0 FUJ HEAVY NDUSTRES LTD.

2 PREFACE This manua covers the troube shooting procedures of Robin RGD600T generator. Carefu observance of the instructions given herein wi resut in better, safer and faster service work. For more detaied instructions of disassembing and reassembing procedures, pease refer to the service manua for RGD35 1 /RGDSOO. CONTENTS Section Page. SPECFCATONS GENERATOR TROUBLE SHOOTNG Votmeter does not work No DC output votage AC output votage is too high AC output votage is too ow Votage at no-oad is norma, but oad cannot be operated WRNG DAGRAM

3 . SPECFCATONS R G D600T Type Revoving-Fied, Sef-Exciting 2-Poe, 3-Phase Frequency 50 Hz 60 Hz i Max VA 6000 VA output 1 Rated 4800 U A 5300 VA Generator AC i i 22OU/38OU ; 7.3A j 12OUf208U 14.7A! Votage Rated r- 230u~400u! Current 7.OA 127U!22OU : 13.9A DC Output t 1 Power Factor 24OU!4 5U 6.7A U-8.3A 0.8 1OOW Votage Reguator CT (Current Transformer) Votage Reguation Within 10% / TYB Robin, Air-Cooed, 4-Cyce, Diese Engine! Mode DY41 D : Dispacement 412CC (25.14 cu.in.) Engine Max. Output 8.OHP!3000 rpm, 8.5HP:3600 rpm Fue Fue Tank Capacity Automotive Type Diese Fue 16 iters (4.2 U.S. ga.) Fue Consumption Oi Capacity Ratio 1.7 iters!hour (3.6 U.S. pints/h) (50Hz) 2.0 iters, hour (4.2 U.S. pints/h) (60Hz) 1.0 iter (2.1 U.S. pints) Revoution 50Hz-3000 rpm, 60Hz-3600 rpm Starting System Hand Crank (Eectric Start Optiona) Length 661 mm (26.0 in.) with r 747 mm (29.4 in.) Dimensions Width 486 mm (19.1 in.) Eectric mm (19.1 in.) Starter i Height 670 mm (26.4 in.) 670 mm (26.4 in.) Dry Weight 128 kg with Eectric 136 kg, (283 bs) Starter (300 bs) -1-

4 . GENERATOR TROUBLE SHOOTNG 1. VOLTMETER DOES NOT WORK. -. Norma votage at termina? (Run the engine) Measure the votage at AC terminas with a circuit tester, whie the 2ngine is running at rated r.p.m. < Remedy > t the votage is norma. repace votmeter. Fig Wiring checked? (Stop the engine) Check a the connections at coupers and connectors. < Remedy > Tighten oose connection. -3. Checking the exciting coi Disconnect the two eads which come out from the exciting coi through the hoe of the crankcase and connected w-ith SR (Siicone Rectifierj in the contro box. (Fig. 2) Fig, Check the resistance between these two eads with a circuit testor. The norma resistance is 1-3 Q. f the resistance is much arg2r or smaer. the exciting coi is defective. Repace Lvith new one. -2-

5 - GENERATOR TROUBLE SHOOTNG f the resistance is norma in Step(b), run the engine at rated r.p.m. without connecting these eads. and check the votage between them with a circuit tester. (AC votage) The norma votage is f the votage is much higher or ower, the exciting coi is defective. Repace n-ith new one. -4. Checking inter-brush resistance a) Remove the brush cover and disconnect the eads from brushes. b) Check the resistance between two terminas of the brushes. (See Fig. 3.) The norma resistance is s1. f the resistance is much arger or smaer. there woud be a faut in the brush or sip rings. Pease check them as foo\\s. a. Remove the brush hoder and check the brushes The brushes must be smooth where they contact the sip rings. f not, poish smooth the brushes with sandpaper. A brush that is not smooth produces arcs between the brush and sip rings eading to possibe damage. Usabe brush engths are from 5 mm to 15 mm as show-i in Fig. 3. X brush shorter than 5 mm must be re- paced because decreased contact pressure betvveen the brush and sip ring owers generator efficienq and output votage. i( Fig. 3 15mm-5mm Fig. 4-3-

6 GENERATOR TROUBLE SHOOTNG - b. Checking the sip rings The sip ring surfaces must be uniformy bright. Sip rings showing back spots. excessive wear, or uneven wear must be repaired. A stained sip ring owers generator efficiency and output votage. Poish the sip rings with fine sandpaper whie turning the rotor unti rough spots disappear. Care shoud be taken not to touch the rotor cois with the sandpaper. (See Fig. 5.) ROTOR SLP RNG \ Fig. 5 c. Checking the inter-sip ring resistance Check the resistance between the two sip rings with a tester. (See Fig. 6.) The resistance is norma if it is anywhere in the range shown on Tabe-. f the resistance is much arger or smaer, the rotor shoud be repaced. Fig Checking the main coi Main coi resistance can be measured at the coupers of wiring harness from stator. Disconnect the coupers and measure the resistance between terminas as numbered in Tabe 2. (See Fig. 7.j < Remedy > f Main coi is found fauty: repace stator. Fig. 7

7 - GENERATOR TROUBLE SHOOTNG irmnal : JMBER LT W i@ Type Hand Start Eectric Start 220/3BOU i20/2oav 22oi3aov 12of2oav 23014OOV 127/22ov 23014OOV 1 127/22OV i 240i415v 240/415U LEAD WRES - i YELLOW YELLOW Exciting Coi SR YELLOW YELLOW Exciting Coi SR s -! - GRAY GRAY Key Switch :s -! - PNK PNK Key Switch i$i : - -, - - 6% LGHT LGHT LGHT LGHT Fied Coi to SR GREEN GREEN GREEN BROWN : BROWN BROWN BROWN Fied Coi to SR CC ORANGE i ORANGE ORANGE ORANGE DC Output (+) BROWN/ BROWN! BROWN! BROWN; DC Output (-) i WHTE WHTE i WHTE, WHTE cc WHTE - WHTE -! Output Wire from Main Coi 17 RED - RED - i Output Wire from Main Coi Thin Wire!@ BLACK - BLACK -! Output Wire from Main Coi v) WHTE! WHTE WHTE WHTE Output Wire from Main Coi (V) $ i@ RED RED j RED RED Output Wire from Main Coi (U) 4T.i - *z i@ BLACK BLACK BLACK BLACK Output Wire from Main Coi (W) cnz GREEN GREEN GREEN GREEN Neutra Wire from Main Coi (0) RED em aou 50Hz 23OJ4OOV GREEN,@ 1.26,c Q 1.26 R : 240!415V 60Hz i 2oi2oau, 127!22OV j 0.23 R Q 0.23 R Tabe 2-5-

8 GENERATOR TROUBLE SHOOTNG Checking the SR (Siicone Rectifier) and CT (Current Transformer) Removing the contro box Remove the contro box from generator frame. Remove the back pane from contro box. Fig Checking the SR Disconnect the connectors of SR and check the inter-termina continuity with a circuit tester. (Tabe 3 j f the SR is found to be defective. repace with new one. Fig. 9 Tester Poarity YELLOW,, Femae \.connectors; YELLOW, Mae \ BROWN connectors; LGHT GREEN YELLOW! - /Femae ) X X X 0 (connectors) - YELLOW One of two One : 3,/Mae 1; mae connector: c> Another: X X 0 \connectors; Another: X - BROWN LGHT GREEN X X X -

9 - GENERATOR TROUBLE SHOOTNG Checking the CT Disconnect the connectors and coupers of CT. Check the inter-termina resistance of CT with a circuit tester. Fig Hz 1 Type Measuring Points Resistance 22Qf38QV Termina 1 and i2 23Of4QOV 24O415V ; Termina 3 and R 60Hz, V 127i22OV! Termina 1 and 2 i Termina 3and 4 i 0.02R Tabe 4 Note: Take k 10% toerance on above resistance vaue. f CT is found tc be fauty, repace with new one. -7-

10 GENERATOR TROUBLE SHOOTNG - 2. NO DC OUTPUT VOLTAGE 2-. s AC votage norma? Check the AC votmeter. f no AC votage is shown on votmeter. check the generator by foowing Step - through Step DC fuse checked? Cehck the FUSE in the fuse hoder. f fuse is bown. check for the cause of fuse bowing, and then repace with new one Wiring checked? Check a the wiring are connected correnty. Fig. 1 < Remedy > Correct wrong wiring and tighten oose connection Checking the diode rectifier Remove the rear cover and check the diode rectifier with a circuit tester. Fig. 72 * : Some resistance appears. -8-

11 - GENERATOR TROUBLE SHOOTNG 2-5. Check the DC coi Check the resistance between two bue eads from stator with a circuit tester. Type 1 Resistance 22OJ38OV 5OHz ; 230/4OOV V 120/208V, 60HZ i 0.12Q 127i22OV! Tabe 6 f the resistance is much higher or much ower than above figures, the DC winding in the stator is broken or short-circuited. Repace stator. 3. AC OUTPUT VOLTAGE S TOO HGH 3-. Check the engine r.p.m. f the engine r.p.m. is too high, adjust it to rated r.p.m Check the wiring Check a the wiring. Correct wrong wiring and tighten oose connection if any Checking the SR (Siicone Rectifier) Check the SR referring to Step Checking the CT (Current Transformer) Check the CT referring to Step

12 GENERATOR TROUBLE SHOOTNG - 4. AC OUTPUT VOLTAGE S TOO LOW 4-. Check the engine r.p.m. f the engine r.p.m. is too ow! adjust it to the rated r.p.m Check the wiring. Check a the wiring. Correct wrong wiring and tighten oose connection Check the inter-brush resistance. Check the inter-brush resistance referring to Step -4. Remedy as instructed in Step Check the main coi. Check the main coi referring to Step -5. f main coi is found fauty. repace stator Check the SR (Siicone Rectifier). Check the SR referring to Step Check the CT (Current Transformer) Check the CT referring to Step ALTHOUGH OUTPUT VOLTAGE S NORMAL AT NO-LOAD, BUT LOAD CANNOT BE OPERATED. 5-. Check the engine r.p.m. f the engine r.p.m. is ow-, adjust it to the rated r.p.m Overoad checked? Check the tota wattage of oad(s) appied to the generator Check the appianceis) f the appiance is defecti\-e, repair or repace it Check the main coi Check the main coi referring to Step -5. f main coi is found fauty, repace stator. 5-S. Check the inter-brush resistance. Check the inter-brush resistance referring to Step -4. Remedy as instructed in Step

13 - GENERATOR TROUBLE SHOOTNG 5-6. Check the generator insuation Stop the engine Connect a megger tester to one of the four.4c output terminas and ground termina, and measure the insuation resistance. The norma insuation 1 MQ. resistance is above f it is ess than 1 MR, disassembe the generator and measure the insuation resistance of the stator, rotor, contro box and CT (Current Transformer) individuay. Fig. 13 STATOR Measure the insuation resistance between the red or white couper from the stator and the core. f it is ess than 1 Mn, repace the stator. Fig. 14. ROTOR Measure the insuation resistance between the core and one of the sip rings of the rotor. f it is ess than 1 MS2, repace the stator. Fig

14 GENERATOR TROUBLE SHOOTNG -. CONTROL BOX Measure the insuation between the ive parts and the casing or grounded part. Cose the no-fuse breaker first, then measure it. Any part which has an insuation resistance of ess than 1 MQ has a fauty insuation, which can cause eectric shock or eakage. Repace such parts. Fig. 16. CURRENT TRANSFORMER Measure insuation resistance between each termina and the core. f it is ess than 1 MS2. repace the current transformer. Fig Check the generator overheating. Check that the cooing air inet is or bocked. Remove the obstaces. cogged 5-8. Check the CT (Current Transformer) Check the CT referring to Step Check the SR (Siicone Rectifier Check the SR referring to Step COOLNG AR NLET -12- Fig. 18

15 . WRNG DAGRAM 120/208V, 127/22OV GENERATOR CONTROL BOX --- C DC LEE -_-_-- _ _--- 1.ei DC BRoWNiWH TE -o-tou E 220/38OV, 230/4OOV, 240/415V GENERATOR CON TROL BOX --.+-YELLOW; *...^ 7BLAC,K- -- SR i!s -T OUTt ) --A-- E - 13-

16 WRNG DAGRAM - FOR ELECTRC START TYPE CONTROL BOX The battery cords have a cross sectiona area of 20 mm?.. SYMBOLS Symbos 1 Parts Name Eng -1 FC Fied Winding B Brush AVR Auto Votage Reguator CT Current Transformer V Votmeter - FPSw Fu Power Switch -- D Diode Stack Assy - SR Siicon Rectifier -- F Fuse REC, AC Output Receptace (Tota 15A Max) REC., AC Output Receptace (OVi2OV) REC, AC Output Receptace (22OV, 23OV!24OV) T DC Output Termina - T, 3-phases Output Termina NFB No Fuse Breaker E Earth Termina (Ground Termina) MG Magneto EC Exciting Coi ChC Charge Coi SM Starting Motor (Eectric Starter) BAT Battery KS Key Switch The wire symbos in the circuit diagrams signify as foows. Use the wire sizes specified mm (AWG No mm (AWG No mm2 (AWG No.14) mm2 (AWG No _ mm2 (AWG No.10) - 14-

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18 @ FUJ HEAVY NDUSTRES LTD. - Engine & Machinery Export Saes Dept - 39th Foor, Shinjuku Mitsui Bdg , Nishi-Shinjuku, Shinjuku-ku, Tokyo, Japan TEL: Tokyo TELEX: CABLE ADDRESS: FUJHEAVY TOKYO PRNTED N JAPAN