Model 911 - Flight Systems
Contents
1. 3687 3950 RV GEN SET CONTROL ONAN 300 3763 5268 RV GEN SET CONTROL ONAN 300 3764 5342 RV GEN SET CONTROL ONAN 300 4296 300 4297 ENGINE MONITOR ONAN 300 4901 4902 RV GEN SET CONTROL ONAN 300 4320 300 4923 RV GEN SET CONTROL ONAN 300 4456 300 5299 RV GEN SET CONTROL If you service ONAN RV GEN SETS you need to meet the G MAN Is the problem with the control board the regulator the windings or other components The G MAN can tell you saving hours of tedious guesswork Available adapters allow testing of dozens of Emerald Marquis Microhte e Camp Power models The SLICK STICK Keeps your gen set properly maintained cleans and re finishes slip rings quickly and safely z O m POINT MAN Fight Systems newest RV Generator Service Tool The Point MAN simply plugs in between the generator and the regulator giving you easy access to eight key circuits needed for effective regulator troubleshooting REBUILDING SERVICE Fight Systems rebuilds over 200 different Onan Kohler Generac Basler ASCO and other Generator ATS Controls Please call or see our website for a complete list 9 FLIGHT SYSTEMS MODEL SII Manual WARRANTY INFORMATION Note Always Refer to the Specific Generator Set Manual when Troubleshooting Problems The Model 305 Generator Voltage Regulator is warranted to be free from defects in materials and workmanship for a period of two years from the date it wa2. and off rapidly 120 times per second The on time is varied to supply the proper field current This current is maintained during the off time by a free wheeling diode in the regulator Continued on Page 4 A FLIGHT SYSTEMS MODEL SII Manual DESCRIPTION Cont VOLTAGE SENSE J4 2 and 3 When the engine starts the generator supplies AC voltage to the voltage regulator J4 pin 2 L1 and J4 pin 3 LO The voltage regulator looks at the amplitude of this AC voltage and makes any necessary corrections to the field current During operation applying or adding loads to the generator decreases the voltage on the sensing terminals The voltage regulator will then increase the DC field current thereby offsetting the voltage drop When loads are removed decreasing load the reverse 1s true Continuously adjusting the field current as load changes is how voltage regulation is achieved VOLTAGE ADJUSTMENT J4 Pins 4 and 5 J4 4 is used for voltage adjustment and J4 5 is connected to the internal return of the voltage regulator An external voltage adjustment potenti ometer is connected between J4 4 and J4 5 J4 1 and J4 6 are not used Refer to Generator Manual FRAME GROUND J4 8 The regulator case 1s connected to frame ground by means of J4 pin 8 This connection serves as a safety ground to insure that the regulator case is at ground potential at all times in addition to the ground provided by
3. means of the mounting bolts WIRE HARNESS An eight inch long pigtail harness from the voltage regulator to the plug is provided The wire is automotive 18 AWG with SLX insula tion designed to withstand vibration and high temperature Each wire is stamped J1 1 thru J1 12 The black wire is on J1 1 A special PVC coated fiberglass jacket protects the harness from abrasion M FLIGHT systems MODEL SII Manual PRE INSTALLATION MAINTENANCE Important It is necessary to perform certain maintenance items prior to installing anew regulator Failure to perform this maintenance will void the warranty and may result in the premature failure of the new regulator ENGINE The engine must be in good running condition so that it can supply the necessary horsepower to the generator under full load The governor must be set at so that the engine runs at the proper RPM for 60 Hz 4 pole 1800 RPM 2 pole 3600 RPM The governor must not be surging even at no load slight surging is normal on cold start up but should go away after a minute or so A dirty or gummed up carbure tor will cause surging The electric automatic choke must be operating properly so that it does not stick or fail to open thereby causing the engine to run excessively rich If any of these problems exist they must be corrected before installing the new regulator Refer to the applicable Onan service manual for your model for engine servicing details GENERATOR Check
4. tion The Model 911 is a metal cased regulator used in all BGD and NHD model commercial mobile gensets beginning with Spec J used with 300 5002 01 control module Note Refer to the specific Onan service manual for your model when servicing these generators Flight Systems has been repairing and building replacement generator controls for nearly 30 years The Model 911 continues our tradition of designing and building products which will not only perform exactly as the original but offer improvements in operation and longevity See Page 9 for our other products amp services Model 911 Regulator Features Include Rugged packaging Weather proof cast aluminum housing Improved resistance to summer heat Designed for long life Latest technology Loads protected from under frequency Loads protected from overvoltage on overspeed Cost Effective replacement Easy installation cut out for socket wrench Se Ss Se j Full Two Year Warranty NOTICE If preventative maintenance procedures see gen set owners manual and Pre Installation Maintenance on pg 5 of this manual have not been performed prior to installing this regulator damage can result such damage is NOT covered under warranty FLIGHT SYSTEMS MODEL SII Manual MODEL SII MOUNTING DIAGRAM 4 To Existing Plug To BACK of Gen I erator MOUNTING The voltage regulator is mounted on the right hand end of the gen erator base by means of two bol
5. v FLIGHT SYSTEMS 207 Hempt Rd Mechanicsburg PA 17050 Phone 717 590 7330 Fax 717 590 7327 www flightsystems com Printed in USA Revised Jan 2013 MODEL SII Replacement For Onan P N 305 O9 Il Voltage Regulator ION m x m eee a M AT 1 5 66 PRE INS TALL i READ P G 9 IN ST AL JAN G i MAINTENANCE 911 REGULATOR_ _ 4 wt We rdv Le YOUR MODEL 911 REGESZ Z L a USER MANUAL ED FLIGHT SYSTEMS 207 Hempt Rd Mechanicsburg PA 17050 Phone 717 590 7330 Fax 717 590 7327 www flightsystems com FLIGHT SYSTEMS MODEL 9II Manual TABLE OF CONTENTS e Model 911 Features e Mounting Diagram Description e Pre Installation Maintenance e Specifications Footprint Diagram Plug Pin Diagram e Warranty Information e Other Products amp Services M ELIGHT SYSTEMS MODEL SII Manual OTHER PRODUCTS amp SERVICES NEW UNITS Flight Systems sells Improved Replacements for these Onan Controls some of which are no longer offered by the Mfg OEM Part Description ONAN 300 C859 GEN SET CONTROL ONAN 300 0679 80 ENGINE CONT MNTR ONAN 300 0681 82 ENGINE CONT MNTR ONAN 300 B1073 B944 RV GEN SET CONTROL ONAN 300 1006 1404 1540 YD REGULATOR ONAN 300 2604 2605 ENGINE MONITOR ONAN 300 2784 2943 RV GEN SET CONTROL ONAN 300 3056
6. ing the rotor DC resistance is particularly important before install ing a new regulator This is your chance to find out if there is a problem that possibly caused the last regulator to fail Unplug regulator Measure the resistance between pins 9 and 10 on the connector that plugs into the regulator It should be between 23 and 28 ohms A reading much lower than 23 ohms indicates a partial short in the rotor A reading much higher than 28 ohms indicates a problem with the brushes slip rings or a bad connection The most likely cause will be dirty or oxidized slip tings so check them first and clean if necessary See Slick Stick Pg 9 If the resistance is still high check the brushes and connections If possible check the stators for grounds See G MAN pg 9 Make sure that the field flash voltage is reaching the regulator by measuring 12 VDC on pin 7 to frame ground during cranking No voltage indicates a control board or wiring problem
7. percent VIBRATION Vibration Resistant Package SIZE See Footprint Diagram Page 7 With external pot 130 a AC VOLTS 5 REGULATED VOLTAGE VS FREQUENCY 6 79 FLIGHT SYSTEMS MODEL SII Manual DESCRIPTION OVERVIEW The Model 911 regulates the voltage output of your generator By constantly monitoring the voltage and frequency output at the stator the Model 911 effectively responds with the proper corrective action even under the most drastic load change To protect loads voltage 1s automatically lowered during underfrequency operation The Model 911 1s rugged weather proof and heat resistant FIELD FLASH VOLTAGE J4 7 When starting the generator set a DC voltage 1s applied to J4 pin 7 of the voltage tegulator from P1 pin 5 of the control module This supplies field current from J4 pin 9 F1 through the rotor to J4 pin 10 F2 QUADRATURE WINDING J4 11 and 12 When the engine starts the generator supplies AC voltage from the quadrature winding stator of the generator to the voltage regulator J4 pin 11 Q1 and J4 pin 12 Q2 This AC voltage is rectified to a DC voltage and is applied to the rotor from J4 9 The voltage regulator also looks at the frequency of this AC voltage and makes any necessary corrections to the rotor current FIELD DRIVE J4 10 The function of J4 10 is to provide the proper current to the rotor under varying load conditions It does this by switching on
8. s sold This date appears on unit label Flight Systems Limited Warranty covers the repair or replacement of defective product within the warranty period It does not cover the cost of installation or removal costs incurred or possible damage to other equipment including the generator or parts thereof as a result of the Model 305 Generator Voltage Regulator Flight Systems or its authorized agent shall reserve the right to determine the cause of malfunction In the case if we determine that it was due to abuse misuse improper installation acts of nature failure to perform recommended gen set maintenance procedure or problems elsewhere in the gen set the warranty claim shall be disallowed and established repair rates shall apply Alteration of the unit in the field will also void warranty Ship defective units directly to FLIGHT SYSTEMS 207 Hempt Rd Mechanicsburg PA 17050 Attention Warranty Service Please prepay all freight charges and note the nature of the failure if known Return Policy Unwanted items may only be returned within 30 days of original purchase date Refund credit issued shall be less a 25 per item restocking re test fee as long as unit is in new undamaged condition Shipping charges are not refundable 8 M FLIGHT SYSTEMS MODEL SII Manual MODEL SII FEATURES The Flight Systems Model 911 was designed as a direct replacement for Onan P N 305 0911 It is an exact fit and requires no modifica
9. ts Hold the regulator with the har ness facing the front The reat bolt goes through the regulator and ground strap and into the threaded bushing in the base Cutouts in the sides of the case provide access for a socket wrench Route the harness and plug under the end of the generator to where it mates with the plug coming from the generator housing Press the plug in firmly until it clicks into place The black sleeve over the harness protects it from abrasion NOTE The genset may have to be slid out to access the regulator M ELIGHT SYSTEMS MODEL SII Manual MODEL SII FOOTPRINT DIAGRAM 3 400 E a DES TOP VIEW 3400 2 250 T SIDE VIEW I 3 600 O9 990991 MODELSII PLUG PIN oocooo DIAGRAM Front View of Plug PINS 1 amp amp ARE NOT USED FLIGHT SYSTEMS MODEL SII Manual SPECIFICATIONS BATTERY VOLTAGE Voltage 12 VDC 2 V FIELD Voltage Range 20 75 VDC Nominal Peak 160 V Current 6 A continuous peak 15 A at 175 E Field Flash 12 VDC with 12 7 VDC battery FREQUENCY RANGE 45 65 Hz Nominal 60 Hz Voltage ramps down with frequency See Table Below VOLTAGE REGULATION 120 V 2 V No load to full load OPERATING TEMPERATURE RANGE To 175 F ISOLATION TO CASE Greater than 10 Meg Case is grounded ENVIRONMENTAL CHARACTERISTICS Unit has a metal case and is intended to be mounted inside of electrical enclosure RELATIVE HUMIDITY 0 100
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