North Star 5000 PG User's Manual
Contents
1. itis connected to a light load or no load such as a power saw it will require less starting current The exact requirement will also vary with the brand or design of the motor Generators respond to severe overnoading differently than the power line When overloaded the engine is not able to supply enough power to bring the electric motor up to operating speed The generator responds to the high initial starting current but the engine speed drops sharply The overload may stall the engine If allowed to operate at very low speeds the electric motor starting winding wil bum out ina short time The generator winding might also be damaged Running the generator under these conditions may result in damage to the generator stator as well as the motor windings Because the heavy surge of current is required foronly an instant the generator will not be damaged if it can bring the motor up to speed in a few seconds If difficulties in starting a motor are experenced turn off all other electrical loads and if possible reduce the load on the electric motor EXTENSION CORDS When electric power is to be provided to various loads at some distance from the generator extension cords can be used These cords should be sized to allow for distance in length and amperage so that the voltage drop between the set and point of use is held to aminimum Current Power Maximum Extension Cord Length ee Load a 0 is 14 watts aa oa on Cord 10 2402. 0 250 150 100 75 20 4800 125 75 50 25 30 7200 60 353 25 10 40 9600 30 15 10 50 12000 15 4 Not recommended CAUTION Equipment damage can result from the low voltage caused by using an extension cord wth a small wie size Use this chart to estimate the total load on your generator Air Conditioner 12 000 Btu 1700 a Battery Charger 20 Amp 500 Belt Sander 3 1000 Chain Saw 1200 Circular Saw 6 1 2 900 Coffee Maker 1000 Compressor 1 HP 2000 a Compressor 3 4 HP 1800 a Compressor 1 2 HP 1400 a Curling Iron 700 Dishwasher 1200 Edge Trimmer 500 Electric Nail Gun 1200 Electric Range one element 1500 Electric Skillet 1250 Furnace Fan 1 3 HP 1200 a Freezer 800 b Hair Dryer 1200 Hand Drill 1 1100 Hand Drill 1 2 875 Hand Drill 3 8 500 Hand Drill 1 4 250 Hedge Trimmer 450 Home Computer 150 Impact Wrench 500 Jet Pump 800 a Lawn Mower 1200 Light Bulb 100 Microwave Oven 700 Milk Cooler 1100 a Oil Burneron Furnace 300 Oil Fired Space Htr 140 000 Btu 400 Oil Fired Space Htr 85 000 Btu 225 Oil Fired Space Htr 30 000 Btu 150 Oven 4500 Paint Sprayer Airless 1 3 HP 600 a Paint Sprayer Airless handheld 150 Radio 200 Refrigerator 600 b Slow Cooker 200 Submersible Pump 1 1 2 HP 2800 a Submersible Pump 1 HP 2000 a Submersible Pump 1 2 HP 1500 a Sump Pu
3. MODEL 5000 PG ITEM 165965 Portable Generator LN Proven Performance OWNER S MANUAL A WARNING M165965A Read this manual Sorious injury or death can result if safety instructions arc not fallowed DANGER Fire hazard Do not operate in a1 enclosure or building Fire or explosion will result Never place this product near combustible materials A DANGER Breathing hazard Poisonous lumes from engine will kill you Do nel operale the generalor in erclosed areas Da nat operate gencrator rear building or inside of buildings Any Questions Comments or Problems Call Customer Service at 1 800 270 0810 THANK YOU Thank you forpurchasing a NorthStar Portable Generator Your machine is designed for long life dependability and the top performance you demand Please take time now to read through this manual so you can better understand the machine s operation maintenance and safety precautions Everyone who operates this generator must read and understand this manual The time you take now will prolong your generator s life and prepare you for its safe operation Enjoy the exceptional performance of your NorthStar Portable Generator IMPORTANT Make certain the operator Reads and understands the manuals pertaining to this machine Is instructed in safe and proper operation of this machine NOTICE K BAR Industries Incorporated reserves the right to make improvements in design and or changes in speci
4. The duplex is a 120 volt V 20 amp A straight blade receptacle National Electrical Manufacturers Association NEMA number 5 20R This receptade accepts NEMA plug numbers 5 15P and 5 20P Each receptacle on the duplex is capable of drawing 17A simultaneougly Reference 13 Circuit Breakers This portable single phase generator has two 17 amp A push to reset circuit breakers to protect against electrical overloads Reference 14 240V Receptacle This device is a 240V 20A NEMA 6 20R receptacle This receptacle accepts a NEMA plug number 6 20P ALWAYS use grounded male plugs The neutral line of the generator is mechanically grounded to the frame Matching NEMA male plugs must always be used Reference 15 Generator Head The electicdty producing part of the generator Reference 16 Warning Instructions Reference 17 Gas Tank Always allow room for gasoline expansion by not filling the gas tank completely full INTRODUCTION Before starting your generator thoroughly study the instructions and cautions in this manual to assure you are fully acquainted with the operation of all components of this generator Proper preparation operation and maintenance wil result in operator safety best perfomance and long life of the generator For detailed engine operation and maintenance always refer to the Tecumseh engine owners manual furnished with the generator Tecumseh refers to the 8 HP engine as a HM80 NorthStar is constantl
5. d local electrical codes Also local Fire Departments must be consulted concerning proper and safe handling procedures for gasoline NEVER connect any generator to any existing electrical system without an isolating UL approved transfer switch installed by a licensed electrician TROUBLESHOOTING Problem Engine wil not start Voltage too low Circuit breaker trips Voltage too high Generator overheating No output voltage Engine lacks power Engine shuts down during operation Possible Causes Low oil level Fouled spark plug Out of fuel Stop switch in OFF position Engine speed too slow Generator is overoaded Defective load connected to generator Defective receptade Generator overoaded Engine speed too high Generator is overoaded Insufficient ventilation Defective load connected to generator Broken orloose wire Defective receptade Defective stator Defective rotor Defective capacitor Generator is overloaded Dirty air filter Out of fuel Low oil level Possible Remedies Fill crankcase to proper oil level Clean or replace spark plug Fill fuel tank Place switch in ON position a Bring generatorto a qualified technidan for adjustment b Reduce the load See Load Application section of this manual a Disconnectload b Replace receptacle c Reduce the load See Load Application section of this manual a Bring generatorto a quali
6. e in good condition Worn bare frayed or otherwise damaged cords can cause electric shock NEVER operate the generator or handle any electrical equipment while standing in water while barefoot while hands are wet or while in the rain or snow Electric shock may result ALWAYS use a ground fault circuit interrupter GFCl in damp or highly electrical conductive areas and on construction job sites to prevent electric shock ALWAYS remove the spark plug or spark plug wire before working on the engine or generator to prevent accdental starting ALWAYS provide adequate ventilation Do not operate generator in any endosed or narrow space Engines consume oxygen and give off deadly carbon monoxide poisonous gas Improper ventilation will cause damage to generator and possible injury to people NEVER touch hot muffler hot exhaust manifold or engine cooling fins ALWAYS remove all oil or gasoline deposits and accumulated dirt from generator and immediate area Keep generator head and engine dean NEVER operate the generator under the following conditions Excessive change in engine speed slow or fast Overheating inload connecting devices Sparking orarcs from generator Loss of electrical output Damaged receptacles Engine misfire Excessive vibration Enclosed compartments or confined areas Flame or smoke Rain snow or wet conditions Operator non attendance gt ACU rToammMVOD WARNING Check fuel
7. fications at any time without incurring any obligation to install them on units previously sold TABLE OF CONTENTS Thank you Specifications Machine component identification Generator features Introduction ANSI safety definitions Rules for safe operation Installation Load application Pre start up preparation Starting Stopping Engine care Generator care Troubleshooting o1 0o Ngae eA aA Aw N N SPECIFICATIONS Item Number Maximum Output Continuous Output Voltage Phase Frequency Regulation Voltage Regulation Power Factor Engine Engine Speed Fuel Type Fuel Capacity Oil Capacity Starting Method 120 V Receptacle 240 V Receptacle Circuit Breaker Grounding Post Dimensions Length Width Height Dry Weight Gross Weight 165965 5000 Watts W 4000 Watts W 120 240 Volt V Single phase 4 wire 56 5 63 3 Hertz Hz 112 129V 1 0 p f 8 HP Tecumseh HM80 3390 3798 RPM Unleaded gasoline 1 gallon 3 8 L 1 63 US quarts 1 5L Recoil 20 Amp A duplex NEMA 5 20R 20 Amp A duplex NEMA 6 20R 17 Amp A thermal push to reset Receives 12 Ga wire or fork terminal 26 00 66 om 19 00 48 cm 17 50 45 om 106 Ib 45 kg 117 Ib 53 kg MACHINE COMPONENT IDENTIFICATION fig 01858 Figure 1 Ref 1 9 J E n ks fe osx _ 2 o CO eles 2028 2 io qo Befsmo2oeg SI5SGNLAN GS OC ogs E E a eazzzgeco OOLHES ose Ojo O OnOsSG6 he ae
8. fied technician for adjustment a Reduce the load See Load Application section of this manual b Make sure there is at least 3 feet of clearance on all sides of generator a Disconnectload b Bring generatorto a qualified technician for repair c Replace receptacle d Bring generatorto a qualified technician for repair e Bring generatorto a qualified technican for repair f Bring generator to a qualified technician for repair a Reduce the load See Load Application section of this manual b Clean or replace air filter a Fill fuel tank b Fill crankcase to proper oil level
9. important to determine the total electrical load before itis connected to the generator The two major factors in determining the life of a generator head are heat build up caused by overloading the generator and corrosive contaminants that can attack the wring insulation If the generator is overloaded the wires become excessively hot and cause the insulation to break down reducing its ability to resist corrosive contaminants Over time the effectiveness of the insulation is eliminated and a dead short can result Always compare the generator nameplate data with that of the equipment to be used to ensure that watts volts amperage and frequency requirements are suitable for operating equipment The wattage listed on the equipment nameplate is its rated output However some equipment may require three to ten times more wattage than its rating on the nameplate as the wattage is influenced by the equipment efficiency power factor and starting system NOTE If wattage is not given on equipment nameplate approximate wattage may be detemined by multiplying nameplate voltage by nameplate amperage VOLTS X AMPS WATTS Example 120V X5A 600W When connecting a resistive load such as incandescent lights heaters or common electric power tools a capacity of up to the generator full rated wattage output can be used When connecting a resistive inductive load such as a fluorescent or mercury light transformers or inductive coils a capaci
10. mp 600 a Table Saw 10 2000 a Television 500 Toaster 1000 Vacuum Cleaner 250 VCR 70 Water Heater 3000 Weed Trimmer 500 a Hard starting motors require 3 to 5 times the rated running watts b These loads may require up to 15 minutes to restart due to its nomal build up of compressor head pressure NOTE For extremely hard to start loads such as air conditioners and air compressors consult the equipment dealer to determine the maximum wattage PRE START PREPARATIONS Your generator has been thoroughly tested prior to shipment from the factory A factory test report has been induded wth this manual However damage can occur during shipping so be sure to check for damaged parts or loose or missing nuts and bolts If the aforementioned problems occur call Customer Service at 1 800 270 0810 GROUNDING All units must be grounded Drive a 3 4 or 1 copper pipe or rod into the ground close to the generator The pipe rod must penetrate moist earth Connect an approved ground clamp to the pipe Run ano 12 Ga wire from the camp to the generator grounding post located on the control panel Do not connect to a water pipe ora ground used by a radio system CAUTION The engine has been shipped without oil Fill the crankcase with oil before trying to start Low oil shut down prevents your generator from starting without sufficient oil OPERATING SPEED The generator must be run at the correct speed in order to
11. nd hand Timed against a wrist watch or a stop watch the dock should be correct within 2 seconds per minute All speed setting adjustments should be done by a qualified technician BEFORE STARTING 1 Make sure the generator is positioned on firm level surface 2 Check the crankcase for oil and maintain at a proper level 3 Check fuel level and fill tank with fresh unleaded gasoline if necessary Allow for gasoline expansion by never filling fuel tank completely to the top Always wipe up and remove any spilled gasoline 4 Make sure that the exhaust fumes are directed away from people STARTING 1 Disconnect all loads to generator 2 Move engine on off lever located on engine to the position 3 For cold engine move choke lever to full choke position Fora warm engine move choke lever to to half choke or run position 4 Grasp recoil handle and pull 5 When engine starts move choke lever to run position 6 Loads may nowbe connected to generator STOPPING 1 Disconnect all loads to generator 2 Move engine on off switch to the O position ENGINE CARE Refer to your Tecumseh Owners Manual for proper care and maintenance CAUTION NEVER change oil on a hot engine the hot oil could cause severe burns GENERATOR CARE The generator head is a two pole 3600 RPM 60 Hz brushless revolving field and synchronous type with one sealed radial roller bearing The rotor of the generator head is directly con
12. nected to the engine crank shaft and the stator is rigidly coupled to the engine casting via the generator head casting Exercising The Generator The generator should be operated every four weeks Wam the unit up by starting the engine and letting it run for 10 to 15 minutes This will dry out any moisture that has accumulated in the windings If left this moisture can cause corrosionin the winding Frequent operation of the engine generator will also ensure that the set is Operating properly should it be needed in an emergency Generator Maintenance The generator head is brushless and maintenance free Any major generator service including the installation or replacement of parts should be performed only by a qualified electrical service technican USE ONLY FACTORY APPROVED REPAIR PARTS Obtain all factory parts from Customer Service at 1 800 270 0810 A Bearing The bearing used in these generators is a heavy duty sealed ball bearing They require no maintenance or lubrication B Receptacles Quality receptacles have been utilized If a receptacle should become cracked or otherwise damaged replace it Using cracked or damaged receptacles can be both dangerous to the operator and destructive to the equipment Stand by Operation If your generator is to be used as a standby electric power source in case of utility failure it must be installed by a registered and licensed electrician and in compliance with all applicable state an
13. produce the proper electrical voltage and frequency The speed of the engine was carefully adjusted atthe factory so that the generator produces the proper voltage and frequency The output voltage should be checked to ensure the generator is working properly before connecting a load to the generator Failure to do so could result in damage to equipment plugged into the unit and possible injury to the individual All engines have a tendency to slow down when a load is applied When the electrical load is connected to the generator the engine is more heavily loaded and asa result the speed drops slightly This slight decrease in speed together wth the voltage drop within the generator itself results in a slightly lower voltage when the generator is loaded to its full capacity than when it is running wth no load The slight variation has no appreciable effect in the operation of motors lights and most appliances Electronic equipment and clocks will be affected if correct RPM is not maintained See Load vs Output chart toad SC utputt C sd z Percent of Generator Generator RPM Hz Voltage at 120V Output Receptade 0 3780 63 0 129V 50 3600 60 0 120V 100 3510 585 112V Output voltage should be checked periodically to ensure continued proper operation of the generating plant and appliances It can be checked with a portable meter Frequency can be checked by using an electric clock with a sweep seco
14. s aes E Vibration Isolation Mount Muffler Gas Cap Engine Stop Switch Recoil Air Geaner Oil Drain Plug Choke Lever Description eae 2 ham 4 ls a 7 8 Fig01857 Figure 2 10 17 GENERATOR FEATURES Reference 1 Muffler Allow 3 clearance around the hot exhaust gas Reference 2 Gas Cap Reference 3 Engine Stop Switch The rocker engine stop switch is located on the engine means ON O means OFF Reference 4 Recoil Grasp firmly when starting engine Reference 5 Air Cleaner Refer to your Tecumseh engine manual for air cleaner care Reference 6 Vibration Isolation Mounts The engine and generator are mounted on rubber cylinders that absorb most ofthe engine vibration This feature eliminates the tendency of the machine to walk which is common in engine powered equipment Reference 7 Oil Drain Plug Refer to your Tecumseh engine manual for oil change recommendations Reference 8 Choke Lever Used during cold starts Refer to the starting stopping instructions and the Tecumseh engine manual for usage Reference 9 Dipstick Reference 10 Protective Frame The frame protects to engine and generator from damage Reference 11 Grounding Screw Ground the generator via the grounding screw to a copper pipe or rod that is driven into moist soil Reference 12 120V Receptacle The generator has a control panel with one duplex two receptades in a common housing receptacle
15. system on a regular basis Look for signs of leaks deterioration chafed or spongy fuel hose loose or missing fuel hose clamps damaged fuel tank or a defective fuel shut off valve Correct any defects before operation WARNING Keep fire extinguisher dose by your generator and be familiar on how to use it Consult your local fire department for correct extinguisher type INSTALLATION OUTDOORS Choose locations where the generator will not be exposed to rain snow or direct sunlight Position the generator on secure level ground soit will nottip or slide down a hill Place the generator so that the exhaust fumes will not be directed towards people The installation site must be free from water moisture or dust All electrical components should be protected from excessive moisture or the insulation system will deteriorate and result in grounding or shorting out the generating system Foreign matters such as dust dirt sand lint or abrasive materials can cause damage to the generator head and engine if allowed into its cooling system NEVER install your generator inside confined areas Inside installation can cause health hazards or death DANGER Remember exhaust fumes are deadly carbon monoxide gas and must be vented to the outside where there are no people Cooling air of sufficient amounts must be allowed to flow in and exhausted out to ensure proper cooling of the engine and generator head LOAD APPLICATION Itis
16. ty of up to 0 6 times the generator s full rated output can be used Always allow the generator to reach operating speed before a load is applied STARTING ELECTRIC MOTORS Electric motors require much more current amps to start than to run Some motors particularly low cost split pbhase motors are very hard to start and require 5 to 7 times more currentto start than to run Capacitor motors are easier to start and usually require 2 to 4 times as much current to start than to run Repulsion Induction motors are the easiest to start and require 1 5 to 2 5 times as much to start than to run Most fractional motors take about the same amount of current to run them whether they are of Repulsion Induction Rl Capacitor Cap or Split Phase SP type The following chart shows the approximate current required to start and run various types and sizes of 120 volt 60 cycle electric motors under various conditions 120V 60 Hz Motors Starting Amps Hp motor Running RI type Cap type SP type Watts 1 6 525 7 11 9 18 16 22 1 4 700 9 15 12 23 22 32 1 3 875 11 18 14 29 26 35 1 2 1175 15 25 20 40 NA 1 1925 24 40 32 64 NA 11 2 2400 30 50 40 80 NA 2 2900 36 60 48 96 NA 3 4075 51 85 68 136 NA 5 6750 84 140 112 224 NA The figures given above are for an average load such as a blower or fan If the electric motor is connected to a hard starting load such as an air compressor it will require more starting current If
17. y improving its products The specificatons outlined herein are subject to change without prior notice or obligation The purchaser and or user shall assume liability of any modification and or alterations on this equipment from original design and manufacture Before using the user shall determine the suitability of this product for its intended use and assumes liability therein ANSI SAFETY DEFINITIONS DANGER indicates an imminently hazardous situation which if not avoided will result in death or seriousinjury This signal wod is to be limited to the most extreme situations WARNING indicates a potentially hazardous situation which if not avoided could result in a death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may resultin minor or moderate injury It may also be used to alert against unsafe practices RULES FOR SAFE OPERATIONS Safety precautions are essential when operating this generator Respectful and cautious operation wil considerably lessen the possibilities of a personal injury This manual will warn of specific personal injury potential and these will be designated by the symbol A WARNING This generator is equipped with a grounding post located on the control panel for your protection Always complete the grounding path from the generator to a copper pipe rod that is driven into moist earth to prevent electrical shock ALWAYS use electrical cords that ar
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