Flight Systems 56-5961-00 User manual

56-5961-00
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User’s Manual

1
Table of Contents
2 | Overview and Features
3 | Unpacking and Inspection
| Removal and Installation
4 | Voltage Adjust
| Factory Default
5 | Troubleshooting
6 | Fault Codes
9 | Warranty Information
Back | Repair and Technical Support

2
Overview and Features
▪Exact replacement for Onan© 300-5961 and 327-1501 control
modules
▪Improved circuit design over OEMs
▪Over-sized heatsink for cooler operation
▪Encapsulated in automotive grade urethane and fully
repairable
▪Contains fault code system for easy troubleshooting
▪Advanced detection system checks condition of brushes,
sliprings, and rotor while cranking. Generator will be
prevented from running if damage is likely. (See Page 5)
▪Communication port for connection to Flight Systems 327v2
modem. Allows for remote monitoring and remote start, (may
not be available upon initial release).
The 56-5961-00, as with all Flight System built devices, comes with
a 2-year warranty and a 30-day return policy upon initial purchase
of the product.

3
Unpacking and Inspection
Be careful when unpacking your new controller so that nothing is
damaged. Do not expose your controller to static shock prior to or
following installation.
Removal and Installation
The controller is accessible through the generator’s front access
door. The housing for the controller is located in the air intake
housing. You may need to unbolt the coolant reservoir to access the
control board location. You should not need to disconnect any
coolant lines.
▪Start by disconnecting the connector cable on the old
control board.
▪Next, remove the three 10mm hex bolts on the cover of the
housing. Once the cover has been removed, the controller
and bracket can be lifted from the intake housing.
▪Unbolt the single 10mm hex bolt threaded into the plastic
mount of the old controller.
▪Installation is reverse of removal. Make sure wire connector
latches properly into control board mating connector.
AFTER THREADING INTO A PLASTIC MOUNT ON THE 56-5961-00, IT
IS CONSIDERED INSTALLED, VOIDING THE 30-DAY RETURN POLICY!

4
Voltage Adjust (within 20 seconds after startup)
Press start 6 times; the status light will begin blinking to signal the
genset is now in voltage adjust mode.
▪Short press START to increase voltage
▪Long press (more than 2 seconds) START to decrease
voltage
Each press will make the voltage adjust by .6v.
Wait for the status light to stop flashing. If the generator goes into
alarm before status light times out the voltage setting will not be
saved.
If the generator needs to be shut down during this operation, hold
stop for two seconds.
Factory Default
To restore all calibrations to factory default:
▪Press the stop button ten times while generator is not
running and not in a fault condition. The status indicator will
come on solid.
▪Hold stop button until status indicator turns off.

5
Troubleshooting
Blinking while Cranking
Causes: normal operation, no issue
No Response at Control Switch
Causes: faulty switch, poor connections, missing connections, or
dead battery
Starter Engages and Disengages
Causes: low cranking voltage
Starting Batteries Don’t Maintain a Charge
Causes: marginal battery, battery connections, or charging system
No AC Power While Controller is Running
Causes: a circuit breaker is off, tripped or malfunctioning, or there
are poor AC harness connections
Engine Surging Without Fault Shutdown
Causes: fuel leaks, restrictions or air bubbles, worn slip
rings/brushes, misadjusted or faulty governor, worn generator
bearing
Testing the Generator’s Windings
This procedure requires an ohmmeter, set on the lowest resistance
scale (usually 200-ohm.) On the control board mating connector,
with the generator NOT RUNNING, measure these points:
▪Pin 1 to Pin 14 –Field winding (rotor) = 20-30 ohms.
▪Pin 3 to Pin 13 –Quadrature winding = 1.5-3.0 ohms.
▪Pin 33 to Pin 34 –Sense Transformer = 500-600 ohms.
▪Circuit breaker 1 (T1 wire) to Ground = .15-.30 ohms.
▪Circuit breaker 2 (T4 wire) to Ground = .15-.30 ohms.
Solid Light while Cranking NEW FEATURE
Causes: open field or high resistance, be sure to check your slip
rings and brushes for continuity

6
Fault Codes
At fault shutdown, the status indicator light will blink to indicate a
shutdown issue. Blinking will continue for 5 minutes and then
stop. To restore blinking after timeout, press the control switch to
STOP briefly, then press STOP 3 times.
No. 1 –Engine Over Temperature
While running, engine coolant temperature was above
239°F/115°C for 10 seconds.
No. 2 –Low Oil Pressure
While running, oil pressure dropped below 14 psi for 3 seconds.
No. 3 –Service Fault
A two-digit second-level fault occurred.
▪Press STOP briefly to activate the two-digit code
indication. The two-digit code consists of 1-5 blinks, a brief
pause, and then 1-9 blinks. The first set of blinks represents
the tens digit and the second set of blinks represents the
units digit. For example, shutdown code No. 32 would be:
blink-blink-blink -pause- blink-blink -long pause and repeat
No. 4 –Over Crank
Cranking time exceeded 35 seconds.
No. 12 –Over Voltage
After voltage regulation was enabled, output voltage was higher
than 150VAC for 75 milliseconds or higher than 138VAC for 3
seconds.
No. 13 –Under Voltage
After voltage regulation was enabled, output voltage was lower
than 108VAC for 5 seconds.
No. 14 –Over Frequency
Frequency was higher than 70Hz for 40 milliseconds or higher than
66Hz for 6 seconds.

7
No. 15 –Under Frequency
Frequency was less than 54Hz for more than 8 seconds.
No. 19 –Actuator Shorted or Open
Before cranking, the controller sensed an open or shorted
governor actuator or wiring.
No. 22 –Actuator Overload
Due to overloaded AC output or poor engine performance, the
controller kept the governor actuator at full-duty cycle for 60
consecutive seconds.
No. 24 –Faulty Engine Temperature Sender
After 10 minutes of running, the controller sensed an open
temperature sender or wiring.
No. 27 –VAC Sense Lost
While running, the controller lost stator AC sensing voltage even
though the field was functioning normally.
No. 29 –High Battery Voltage
Before cranking, the controller sensed that incoming battery
voltage was greater than 19.2 volts for 5 milliseconds, or greater
than 19.2 volts for 1 second, while running.
No. 32 –Starting Fault
The controller could not detect cranking speed for 12 seconds.
Possible open quadrature winding or broken brushes/dirty
sliprings.
No. 35 –EE Checksum Fault
During startup, the controller detected an EE memory error.
No. 36 –Mechanical Fault
While running, engine speed fell to less than 1000RPM for .5
seconds, un-commanded by controller. This code can come up
when genset runs out of fuel.
No. 38 –Field Overload
While running, field voltage was higher than 180VAC for 10
seconds.

8
No. 41 –Generator Rotor Short
During cranking, the controller sensed that the field circuit/rotor
was shorted to ground.
No. 42 –ROM Fault
During startup, the controller detected a ROM memory error.
No. 43 –RAM Fault
During startup, the controller detected a RAM memory error.
No. 45 –Speed Sense Lost
After crank disconnect, the controller lost speed sense for .25
seconds.
No. 48 –Loss of Field Sense
While running, the field sense circuit on the controller failed, or
field voltage dropped to zero.
No. 57 –Over Prime
The local or remote switch was held in the prime/stop position for
more than 3 minutes.

9
Warranty Information
This Flight Systems manufactured replacement controller is
warranted to be free from defects in materials and workmanship
for a period of two years from the date it was sold.
Flight Systems Limited Warranty covers the repair or replacement
of defective products within the warranty period. It does not cover
the cost of installation, removal costs incurred, or possible damage
to other equipment (including the generator or parts thereof) as a
result of this product.
Flight Systems (or its authorized agent) shall reserve the right to
determine the cause of malfunction. If we determine that it was
due to abuse, misuse, improper installation, acts of nature (such as
storm), failure to perform recommended genset maintenance
procedure or problems elsewhere in the genset, the warranty
claim shall be dissolved and established standard repair rates
apply.
Flight Systems 30-Day Return Policy is only valid for 30 days after
initial purchase of any Flight Systems product. Installation of any
products will result in termination of the 30-Day Return Policy on
that product. Refund/Credit issued shall be less a 25% per item
restocking and testing fee as long as the product is in new
undamaged condition. Shipping charges are non-refundable.

Repair and Technical Support
If this product suffers a failure when out of warranty it can be
rebuilt. As with all generator controllers rebuilt by Flight Systems a
one-year warranty will be issued upon repair.
Be sure to fill out then print our Repair Shipping Form at
FlightSystems.com and include it with any repairs. Repairs can be
shipped to:
Flight Systems
207 Hempt Road
Mechanicsburg, PA 17050 –Attn: Repair
Any repairs not sent with proper contact information will be held
for no more than 6 months from the date received before being
recycled by Flight Systems.
Technical support is also available by phone or online for all Flight
Systems products:
Phone: [phone]
Email: [e-mail]
Open Monday-Friday, 8am-5pm EST