305 Man
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1. RELATIVE HUMIDITY 0 95 percent VIBRATION Vibration Resistant Package SIZE See Footprint Diagram Page 7 SPECIFICATIONS REGULATED VOLTAGE VS FREQUENCY 5 4 FLIGHT SYSTEMS MODEL 826 Manual FLIGHT SYSTEMS MODEL 826 Manual 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 L0 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 is 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 is connected to the internal return of the voltage regulator For 60 Hz an external jumper is connected between J4 4 and J4 5 for 50 Hz a potenti ometer is connected here J4 1 is not used Refer to Generator Manual FRAME GROUND J4 8 The regulator case is 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 pro vided b2. 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 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 reach ing the regulator by measuring 12 VDC on pin 7 to frame ground during cranking No voltage indicates a control board or wiring problem 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
3. DIAGRAM MOUNTING The voltage regulator is mounted on the end of the generator housing by means of the existing Onan bracket 305 0825 02 and two bolts Hold the regulator with the harness facing the front The upper bolt goes through the regulator and bracket into the threaded hole in the housing The lower bolt goes through the regulator directly into the bracket Cutouts in the sides of the case provide access for a socket wrench While mounting the regulator it is important to route the harness and plug under the end of the generator housing and up through the slot in the control compartment The black sleeve over the harness protects it from abrasion MODEL 826 FOOTPRINT DIAGRAM Toward Engine To Existing Plug MODEL 826 PLUG PIN DIAGRAM Front View of Plug 6 3 FLIGHT SYSTEMS MODEL 826 Manual FLIGHT SYSTEMS MODEL 826 Manual OVERVIEW The Model 826 regulates the voltage output of your generator By constantly monitoring the voltage and frequency output at the stator the Model 826 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 Model 826 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 on 300 3056 3590 or P1 3 on 3
4. 00 3764 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 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 DESCRIPTION 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 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
5. Camp Power models The SLICK STICK Keeps your gen set properly maintained cleans and re finishes slip rings quickly and safely 1 8 FLIGHT SYSTEMS MODEL 826 Manual The Flight Systems Model 826 was designed as a direct replacement for Onan P N 305 0826 It is an exact fit and requires no modifica tion The Model 826 is a metal cased regulator used in all Marquis models BGM and NHM series 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 826 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 826 Regulator Features Include 1 Rugged packaging 2 Weather proof cast aluminum housing 3 Improved resistance to summer heat 4 Designed for long life 5 Latest technology 6 Loads protected from under frequency 7 Loads protected from overvoltage on overspeed 8 Cost Effective replacement 9 Ease of installation cut out for socket wrench 10 Full Two Year Warranty FLIGHT SYSTEMS MODEL 826 Manual Note Always Refer to the Specific Generator Set Manual when Troubleshooting Problems The Model 826 Generator Voltage Regulator is warranted to be free from defects in materials and workmanship for a period
6. FLIGHT SYSTEMS 505 Fishing Creek Road Lewisberry PA 17339 Phone 717 932 9900 Fax 717 932 9925 w w w f l i g h t s y s t e m s c o m M O D E L 8 2 6 Replacement For Onan P N 3 0 5 0 8 2 6 Voltage Regulator USER MANUAL Installation Operation FLIGHT SYSTEMS 505 Fishing Creek Road Lewisberry PA 17339 Phone 717 932 9900 Fax 717 932 9925 w w w f l i g h t s y s t e m s c o m Printed in USA Revised Nov 2006 NOTICE READ PG 5 PRE INSTALLATION MAINTENANCE BEFORE INSTALLING YOUR MODEL 826 REGULATOR TABLE OF CONTENTS Model 826 Features 1 Mounting Diagram 2 Description 3 Pre Installation Maintenance 5 Specifications 6 Footprint Diagram 7 Plug Pin Diagram 7 Warranty Information 8 Other Products amp Services 9 9 FLIGHT SYSTEMS MODEL 826 Manual FLIGHT SYSTEMS MODEL 826 Manual 9 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
7. ONAN 300 0681 82 ONAN 300 B1073 B944 ONAN 300 1006 1404 1540 ONAN 300 2604 2605 ONAN 300 2784 2943 ONAN 300 3056 3687 3950 ONAN 300 3763 5268 ONAN 300 3764 5342 ONAN 305 0809 01 0851 0782 ONAN 305 0911 ONAN 332 1268 ONAN 332 1956 Description GEN SET CONTROL ENGINE CONT MNTR ENGINE CONT MNTR RV GEN SET CONTROL YD REGULATOR ENGINE MONITOR RV GEN SET CONTROL RV GEN SET CONTROL RV GEN SET CONTROL RV GEN SET CONTROL RV GEN SET REGULATOR COMMERCIAL GEN SET VR VR21 REGULATOR VR21 REGULATOR REBUILDING SERVICE Flight Systems rebuilds over 200 different Onan Kohler Generac Basler ASCO 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 Engine Protection That Works Our Model 540 offers control and protection for fully automatic gen sets and other standby engines The ENGINE SAVER provides the ultimate in protection having prevented destruction of thousands of engines throughout the world since 1980 Contact our Marine amp Industrial Controls Dept for details 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 Mar quis Microlite amp
8. 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 dam age to other equipment including the generator or parts thereof as a result of the Model 826 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 505 Fishing Creek Road Lewisberry PA 17339 Attention Warranty Service Please prepay all freight charges and note the nature of the failure if known WARRANTY INFORMATION MODEL 826 FEATURES 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 prior to installing this regulator damage can result such damage is NOT covered under warranty 2 7 FLIGHT SYSTEMS MODEL 826 Manual FLIGHT SYSTEMS MODEL 826 Manual MODEL 826 MOUNTING
9. y 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 DESCRIPTION Cont PRE INSTALLATION MAINTENANCE 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 Onan service manual for your model for engine servicing details GENERATOR Checking the rotor DC 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
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