MODEL 305-3 - Flight Systems
Contents
1. 10 is to provide the proper current to the rotor under varying load conditions It does this by switching on and off rapidly 100 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 FLIGHT SYSTEMS MODEL 305 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 1 4 and 5 J4 1 and 4 are tied together internally in the voltage regulator and J4 5 1s connected to the internal return of the voltage regulator For 50 Hz a potentiometer is connected between J4 4 and J4 5 Refer to Generator Manual EXTERNAL CAPACITOR J4 8 and 6 The external capacitor on top of the original Onan voltage regulator has been incorporated into the printed circuit2. 3763 5268 ONAN 300 3764 5342 ONAN 300 4296 4297 ONAN 300 4320 300 4923 ONAN 300 4901 300 4902 ONAN 332 1268 332 1956 ONAN 305 0897 305 0897 ONAN 305 911 Description GEN SET CONTROL ENGINE CONT MNTR ENGINE CONT MNTR ATS TIME DELAY MOD RV GEN SET CONTROL YD REGULATOR ENGINE MONITOR RV GEN SET CONTROL VOLTAGE REGULATOR RV GEN SET CONTROL RV GEN SET CONTROL RV GEN SET CONTROL ENGINE MONITOR RV GEN SET CONTROL RV GEN SET CONTROL VR21 REGULATOR MICROLITE 2 8 VR EMERALD COMM VR 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 Jj adapters allow testing of dogens of Emerald Marquis Microlite FE Camp Power models New fot 2011 The Point MAN This inexpensive breakout box is a fast and easy way to check 8 cicuits needed for elective regulator troubleshooting The SLICK STICK Keeps your gen set properly maintained zu and re finishes slip rings quickly and safely 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 305 Manual WARRANTY INFORMATION Note Always Refer to the Specific Generator Set Manual when Troubleshooting Problems
3. 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 was 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 FLIGHT SYSTEMS MODEL 305 Manual M
4. board on F S Model 305 3 The two wires with Fast On terminals that connected the external capacitor J4 8 and J4 6 are not connected to the Model 305 3 Regulator and 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 SXL 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 maintenance items prior to installing a new regulator Failure to perform this maintenance will void the warranty and may result in the i 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 50 Hz 4 pole 1500 RPM 2 pole 3000 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 the
5. external A capacitor See below i MOUNTING The 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 regulator is held in place by placing the back square mounting foot of the enclosure under the post in the rear of the generator housing NOTE The external capacitor on top of the original Onan voltage regulator has been incorporated directly into the printed circuit board on F S Model 305 3 The two wires with Fast On terminals that connected the external capacitor J4 8 and J4 6 are not connected to the Model 305 3 Regulator and should be taped MODEL 305 Manual FLIGHT SYSTEMS MODEL 305 3 FOOTPRINT DIAGRAM 47 MOI LoTR 3 97 ly TOP VIEW CASE DIMENSIONS SIDE VIEW MODEL 305 3 PLUG PIN DIAGRAM Front View of Plug 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 E Field Flash 12 VDC with 12 7 VDC battery FREQUENCY RANGE 40 55 Hz Nominal 50 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 E ISOLATION TO CASE Greater than 10 Meg ENVIRONMENTAL CHARACTERISTI
6. v FLIGHT SYSTEMS 207 Hempt Rd Mechanicsburg PA 17050 Phone 717 590 7330 Fax 717 590 7327 www flightsystems com Printed in USA Issued Jan 2013 MODEL 305 3 Replacement For Onan P N s 305 0809 03 305 0866 50 Hz Voltage Regulator ea m 1 L P6 pRE INSTALLATION rack READ PG a NOTICE P ONCE BEFORE INSTAL TENANCE BET MEN MODEL 305 REGULATOR a ee p ec p ce ae Le USER MANUAL vr FLIGHT SYSTEMS 207 Hempt Rd Mechanicsburg PA 17050 Phone 717 590 7330 Fax 717 590 7327 www flightsystems com aa pe ce ccc E FLIGHT SYSTEMS MODEL 305 Manual TABLE OF CONTENTS e Model 305 Features Mounting Diagram e Description e Pre Installation Maintenance e Specifications Footprint Diagram Plug Pin Diagram e Warranty Information e Other Products amp Services S 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 ONAN 300 C859 ONAN 300 0679 80 ONAN 300 0681 82 ONAN 300 0921 0922 300 1188 ONAN 300 B1073 B944 ONAN 300 1006 1404 1540 ONAN 300 2604 2605 ONAN 300 2784 2943 ONAN 300 2880 ONAN 300 3056 3687 3950 ONAN 300
7. CS 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 Footprint Diagram Page 7 130 a AC VOLTS 5 REGULATED VOLTAGE VS FREQUENCY 6 FLIGHT SYSTEMS MODEL 305 Manual DESCRIPTION OVERVIEW The Model 305 regulates the voltage output of your generator By constantly monitoring the voltage and frequency output at the stator 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 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
8. ODEL 305 3 FEATURES The Flight Systems Model 305 3 was designed as a direct replacement for Onan P N 305 0809 03 this P N is used in NHE and BGE EM ERALD Series RV Gen Sets We lengthened the harness to allow it to also replace Onan P N 305 0866 Note Always refer to the specific generator manual when troubleshooting problems Flight Systems has been repairing and building replacement generator controls for over 30 years The Model 305 3 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 3 Regulator Features Include Rugged packaging Weather proof housing Improved resistance to summert heat Designed for long life Latest technology Loads protected from under frequency Loads protected from overvoltage on overspeed Cost Effective replacement Ease of installation di cle E a E j gt Full Two Year Warranty NOTICE f preventative maintenance procedures see gen set owners manual and Pre Installation Mainte nance 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 305 Manual MODEL 305 3 MOUNTING DIAGRAM i To Existing i LN Plug pe Z S ee DY go Pm mM OO OE Oe C i NOTE No connection is required to the
9. y must be corrected before installing the new regulator Refer to the applicable Onan service manual for your model for engine servicing details GENERATOR Checking 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 shortin 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 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
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