305 Man - Flight Systems
Contents
1. should be taped The function of this capacitor is to filter the rectified voltage applied to J4 9 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 FLIGHT SYSTEMS MODEL 305 Manual PRE INSTALLATION MAINTENANCE Important It is necessary to perform certain mainte nance items prior to installing a new 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 gover nor 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 carburetor 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 Re fer to the applicable O nan service manual for your model for engine servicing details GENERATOR Checki2. EB FLIGHT SYSTEMS 505 Fishing Creek Road Lewisberry PA 17339 Phone 717 932 9900 Fax 717 932 9925 www flightsystems com MEMBER Printed in USA Revised N ov 2006 MODEL 305 Replacement For Onan P N s 305 0809 01 305 0826 305 0851 305 0782 0 4 305 0830 01 Voltage Regulator M USER MANUAL Installation Operation I FLIGHT SYSTEMS 505 Fishing Creek Road Lewisberry PA 17339 Phone 717 932 9900 Fax 717 932 9925 www flightsystems com FLIGHT SYSTEMS MODEL 305 Manual TABLE OF CONTENTS Model 305 Features eere 1 Mounting Diagram eene eee enne FIRGSCHDLIOB Sesobereru xe Ere d DIPNESRETHPEO T 3 Pre Installation Maintenance D S SPECI Call ONS seisoriesisecreiran ereer NR EIE NEEN 6 Footprint Diagram eene 7 Plug Pin Didgralh oorr er ree da taenes 7 e Warranty Information eene 8 e Other Products amp Services 9 FLIGHT SYSTEMS MODEL 305 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
3. ONAN 300 2784 2943 RV GEN SET CONTROL ONAN 300 3056 3687 3950 RV GEN SET CONTROL ONAN 300 3763 5268 RV GEN SET CONTROL ONAN 300 3764 5342 RV GEN SET CONTROL ONAN 332 1268 VR21 REGULATOR ONAN 332 1956 VR21 REGULATOR _ lf you service ONAN RV GEN SETS you need to P meet the G MAN Is the problem with the control E board the regulator the windings or other components The Em 1 G MAN can tell you saving hours of tedious guesswork rr J A vailable adapters allow testing of T of E merald M ar REBUILDING SERVICE Flight Systems rebuilds over 200 different Onan Kohler Generac Basle A SCO and other Generator amp ATS Controls Please call or see our website for a complete list ENGINE GENERATOR PROTECTION CONTROLS We offer a variety of rugged products which provide E ngine Protection T hat W orks Our Mode 540 offers control and protection for fully automatic gen sets and other standby engines The ENGINE SAVER provides the ultimate in protedion having prevented destrudion of thousands of engines throughout the world since 1980 Contact our Marine amp Industrial Controls D ept for details 9 FLIGHT SYSTEMS MODEL 305 Manual WARRANTY INFORMATION Note Always Refer to the Specific Generator Set Manual when Troubleshooting Problems The Model 305 G enerator Voltage Regulator is warranted to be free from defects in materials and workmanship for a period of two years fro
4. ator is held in place by placing the back square mounting foot of the enclosure under the post in the rear of the gen erator housing NOTE T he external capacitor on top of the origi nal Onan voltage regulator has been incorporated directly into the printed circuit board on F S Model 305 The two wires with Fast On terminals that connected the external capacitor 4 8 and J4 6 are not connected to the Model 305 Regulator and should be taped NOTE No connection is required to the external capacitor See below F FLIGHT SYSTEMS MODEL 305 Manual MODEL 305 FOOTPRINT DIAGRAM 0 4807 e PLACES 3 375 3 300 TOP VIEW CASE DIMENSIONS L 2 850 e SIDE VIEW MODEL 305 i9 i MUGPN oa Front View of Plug 4 5 AMCA FLIGHT SYSTEMS MODEL 305 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 F 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 1752 F ISOLATION TO CASE Greater than 10 Meg ENVIRONMENTAL CHARACTERISTICS Unit has a plastic case and is intended to be mounted inside of electrical enclosure RELATIVE HUMIDITY 0 95 percent VIBRATION Vibration Resistant Package SIZE See F
5. eshooting problems While the Model 305 will function properly as a replacement for the 305 0826 it is not an exact fit As of Nov 2006 we do offer an exact fit replacement our Model 826 Flight Systems has been repairing and building replacement generator controls for nearly 30 years The Model 305 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 305 Regulator Features Include 1 Ruggedpackaging 2 Weatherproof housing 3 Improved resistance to summer heat 4 Designed forlong life 9 Latesttechnology 6 Loads protected from under frequency 7 Loads protected from overvoltage on overspeed 8 Cost Effective replacement 9 Ease of installation 10 Full Two Year Warranty NOTICE If preventative maintenance procedures see gen set owners manual and Pre Installation Mainte nance on pg 5 of this manual have not been performed pnorto installing this regulator damage can result such damage is NOT covered under warranty FLIGHT SYSTEMS MODEL 305 Manual MODEL 305 MOUNTING DIAGRAM a gt Sg 4 S MOUNTING T he voltage regulator is mounted inside the generator housing directly behind the control panel The voltage regulator is held in place by one nut and bolt accessible from the front opening of the housing The back of the regul
6. m the date it was sold T his 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 dam age 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 im proper installation acts of nature failure to perform recom mended gen set maintenance procedure or problems elsewhere in the gen set the warranty claim shall be disallowed and estab lished repair rates shall apply Alteration of the unit in the field will also void warranty Ship defective units directly to FLIGHT SYSTEMS 905 Fishing Creek Road Lewisberry PA 17339 Attention Warranty Service Please prepay all freight charges and note the nature of the failure if known FLIGHT SYSTEMS MODEL 305 Manual MODEL 305 FEATURES The Flight Systems Model 305 was designed as a direct replacement for Onan P N 305 0809 01 this P N is used in NHE and BGE EMERALD Series RV Gen Sets In Nov 2002 we lengthened the harness to allow it to also replace Onan P N s 305 0851 amp 305 0826 used in various Emerald amp Marquis models Note Always refer to the specific generator manual when troubl
7. ng the rotor D C resistance is particularly important before in stalling a new regulator This is your chance to find out if there is a problem that possibly caused the last regulator to fail Unplug regula tor 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 rings so check them first and clean if necessary See Slick Stick Pg 9 1f 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 reach ing the regulator by measuring 12 VD C on pin 7 to frame ground during cranking No voltage indicates a control board or wiring problem D
8. ootprint Diagram Page 7 AC VOLTS REGULATED VOLTAGE VS FREQUENCY 6 FLIGHT SYSTEMS MODEL 305 Manual DESCRIP TION OVERVIEW The Model 305 regulates the voltage output of your generator By constantly monitoring the voltage and frequency output at the sta tor the Model 305 effectively responds with the proper corrective action even under the most drastic load change To protect loads voltage is automatically lowered during underfrequency operation The 305 is rugged weather proof and heat resistant FIELD FLASH VOLTAGE J4 7 When starting the generator set a DC voltage is applied to J4 pin 7 of the voltage regulator from the control P C Board assembly P1 5 This supplies field current from J4 pin 9 F1 through the rotor to J4 pin 10 F2 QUADRATURE WINDING J41 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 J410 The function of J4 10 is to provide the proper current to the rotor under varying load conditions It does this by switching on and off rapidly 120 times per second The on time is varied to supply the proper field current Thi
9. s current is maintained during the off time by a free wheeling diode in the regulator Continued on Page 4 FLIGHT SYSTEMS MODEL 305 Manual DESCRIPTION Cont VOLTAGE SENSE J4 2 and 3 When the engine starts the generator supplies AC voltage to the volt age 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 D uring 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 is true Continuously adjusting the field current as load changes is how voltage regulation is achieved VOLTAGE ADJUSTMENT J4 Pins 1 4 and 5 4 1 and 4 are tied together internally in the voltage regulator and J4 5 is connected to the internal return of the voltage regulator For 60 Hz an extemal jumper is connected between J4 4 and J4 5 for 50 Hz a potenti ometer is connected here 4 1 is not used Ree to G enerator M anual EXTERNAL CAPACITOR J4 8 and 6 The external capacitor on top of the onginal Onan voltage regu lator has been incorporated into the printed circuit board on F S Model 305 T he two wires with Fast O n terminals that connected the external capacitor J4 8 and J4 6 are not connected to the Model 305 Regulator and
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