Northern Industrial Tools 10000 BDG User's Manual
Contents
1. POWER TRANSMISSION The recommended method to transfer the power from the engine to the generator is by using sheaves pulleys and a V belt The generator shaft is 28 mm diameter X 2 38 long with a 8mm key way The table below shows the recommended horsepower and sheaves The shaft speed of the generator must be between 3480 3780 RPM Atno load the correct speed is 3780 RPM f the engine is a 3750 RPM engine then a Double Sheave Dia Double Sheave Dia Engine Hp V Belt Type V Belt Type Quantity Quantity 6 60 6 00 18 Hp B Belt 3VX Belt 2 2 sheave diameter ratio of 1 1 should be used This means that the diameter of the sheave on the engine is the same as the diameter of the sheave on the generator If smaller than recommended sheaves are used the life of the belt will be shortened The possibility of belt slippage also increases with a smaller sheave The engine and generator should be mounted to a plate or surface that can withstand the oonstant vibration and stresses that will be produced See figure 3 for a possible mounting configuration DOUBLE PULLEY I USED IN GONIUNCTION WITH A NOTCHEO V BELT TENSION SDE SLACK SME IF TENSIONER PLLLE 15 USED PLACE SDE Of BELT Figure 3 NOTE Guards are removed to show details DANGER Always have proper guar of the V belt s and sheaves to prevent access to any pinch points Failure to guard the power transmission mechanisms may resultin serious inj2. 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 Pump 600 a Table Saw 10 2000 a Television 500 Toaster 1000 Vacuum cleaner 250 VCR 70 Water Heater 3000 a Hard starting motors require 3 to 5 times the rated tunning 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 UP PREPARATIONS Your generator has been thoroughly tested priorto shipment from the factory However damage can occur during shipping so be sure to check for damaged parts loose or missing nuts and bolts If the aforementioned problems occur call customer service at 1 800 270 0810 Weed Trimmer 500 GROUNDING All units must be grounded Drive a 3 4 or 1 copper pipe or rod into the ground dose to the generator The pipe rod must penetrate moist earth Connect an approved ground clamp to the pipe Run a 10 gauge wre from the clamp to the generator ground screw Do not connect to a water pipe or a ground used by a radio system OPERATING SPEED The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency The output voltage should be
3. checked to ensure the generator is working properly subsequent to 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 as a result the speed drops slightly This slight decrease in speed together with the voltage drop within the generator itself results in a slightly lower voltage when the generatoris loaded to its full capacity than when it is running wth no load The slight variation has no appredable effect in the operation of motors lights and most appliances Electronic equipment and clocks will be effected if correct RPM is not maintained See Load vs Output chart Load Output Percent of Speed Frequency Generator Generator RPM Hz voltage at 120V Output Receptacle 0 3780 63 0 125V 50 96 3600 60 0 122V 100 96 3480 58 0 118V 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 second hand Timed against a wrist watch ora stop watch the dock should be correct within 2 seconds per minute All speed setting adjustments should be done by a qualified technidan GENERATOR CARE The
4. 16 grade 5 bolts Mounting plates item 165935 for mounting generator to a cement pad are available through Northern and the NorthStar parts catalog Reference 11 Fan Vents Never block the vent slots or insert objects through the slots The dosest object should be a minimum of 3 feet away from the vents INTRODUCTION Before attempting to mount 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 will result in operator safety best perfomance and long life of the generator NorthStar is constantly improving its products The specifications outlined herein are subject to change without pror notice or obligation The purchaser and or user assumes 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 serious injury This signal word isto 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 re
5. MODEL 10000 BDG ITEM 165928 Belt Driven Generator M165928A 00287 10000 BDG Any Questions Comments or Problems Call Customer Service at 1 800 270 0810 Hours Monday Friday 7 30 AM to 5 30 PM Saturday 7 30 to 11 30 AM Central Standard Time THANK YOU Thank you for purchasing a NorthStar Belt Driven 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 perfomance of your NorthStar Belt Diiven Generator IMPORTANT If this machine is used by anyone who is not the owner oris loaned or rented make certain the operator Isinstructed in the safe and properoperation of this machine Reads and understands the manuals pertaining to this machine NOTICE K BAR Industries Incorporated reserves the right to make improvements in design and or changes in spedfications 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 forsafe operation Installation Load applicat
6. ce 4 Voltmeter Voltmeter needle should be in green area during all generator load conditions The black line in the center on the green area is 120V During no load conditions the needle should be at or above the black line References 5 6 120V Receptacles e Reference 5 The generator hasa side panel with two 120 volt V 20 amp A straight blade receptacle duplexes two receptacles in a common housing National Electrical Manufacturer s Association NEMA numberis 5 20R e Reference 6 This twistlock is a 120V 30A receptacle NEMA number L5 30R This receptacle accepts NEMA plug number L5 30P which is supplied with the generator Reference 7 120 240V Receptacle This straight blade receptacle is 120 240V 50A but has two 40A drcuit breakers to limit maximum current This receptacle accepts a NEMA plug number 14 50P which is supplied with the generator 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 8 28 mm diameter Shaft The shaft is 2 375 long and has a 8 mm key way A taper bore or split bore bushing is recommended for attaching sheaves 8mm X 1 75 key supplied with generator Reference 9 Ground Screw Ground the generator via the ground screw to a copper pipe or rod that is driven into moist soil Reference 10 Mounting feet Use these three locations to attach the generator head in place with 7
7. ctric motor is connected to a hard starting load such as an air compressor it will require more starting current If 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 electiic motor starting winding wil bum out in a short time The generator head winding might also be damaged Running the generator underthese conditions may result in damage to the generator stator as well as the electric motor windings Because the heavy surge of current is required for only an instant the generator will not be damaged if it can bring the motor up to speed in a few seconds f difficulties in starting a motor are experienced 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 poin
8. ed areas Inside installation can cause health hazards or death LOAD APPLICATION Itis 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 attack the wiring insulation If the generator is overloaded the wires become excessively hot and cause the insulation to break down redudng its ability to resist corrosive BRACKET 18D 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 z 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 connec
9. generator head is a two pole 3600 RPM 60 Hz brushless revolving field and synchronous type with two sealed radial roller bearings Proper care and maintenance are necessary to ensure a long trouble free life Exercising The Generator The generator should be operated every four weeks This is accomplished by starting the engine and applying a load for 10 to 15 minutes This will dry out any moisture that has accumulated in the windings If left this moisture can cause corroson in the winding Frequent operation of the 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 induding the installation or replacement of parts should be performed only by a qualified electrical service technidan USE ONLY NorthStar APPROVED REPAIR PARTS AVAILABLE AT 1 800 270 0810 A Bearing The bearings used in this generator are a heavy duty sealed ball bearing type 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 A WARNING 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 registe
10. ion Pre start up preparation Generator care Troubleshooting SPECIFICATIONS Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Minimum Recommended Engine Engine Speed 120V Receptacle 120 240V Receptacle Circuit Breaker Drive Shaft Dimensions Length Width Height Gross Weight 165928 10000 Watts W 9600 Watts W 120 240 Volt V Single phase 4 wire 58 0 63 0 Hertz Hz 1 0 p f 18 Hp 3480 3780 RPM 2 20 Amp A duplex NEMA 5 20R 30 Amp A twistlock NEMA L5 30R 50 Amp A Straight blade NEMA 14 50R 2 20 Amp A thermal push to resetstyle 30 Amp A thermal push to resetstyle 2 40 Amp A thermal push to resetstyle 28 mm diameter X 2 38 8mm X 1 75 key way 19 50 49 5 cm 14 25 36 2 cm 9 00 22 9 cm 110 Ib 50 kg MACHINE COMPONENT IDENTIFICA TION 00289 1 40A Circuit Breakers 7 120 240V 50A Receptacle 2 30A Circuit Breaker 8 28 mm shaft 3 20A Circuit Breakers 9 Grounding screw 4 Voltmeter 10 Mounting feet 5 120V 20A Duplex Receptades 11 Fan vents 6 120V 30A Twistlock Receptacle 00290 Figure 2 Ref 8 11 3 GENERATOR FEATURES References 1 3 Circuit Breakers e Reference 1 two 40 amp A push to reset circuit breakers e Reference 2 one 30 amp A push to reset circuit breaker e Reference 3 two 20 amp A push to reset circuit breakers Referen
11. isconnectload b Bring generator to a qualified technidan for repair c Replace receptade d Bring generatorto a qualified technidan for repair e Bring generatorto a qualified technidan for repair f Bring generatorto a qualified technidan for repair g Bring generatorto a qualified technidan for repair h Tighten or replace belt s tighten or replace coupl
12. nd possible inggg39 people 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 A Excessive change in engine speed slow or fast Overheating in load 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 Without proper guarding in place rommoomu WARNING Keep fire extinguisher dose by your generator and be familiar with how to use it Consult your local fire department for correct extinguisher type INSTALLATION OUTDOORS Choose a location where the generator will not be exposed to rain snow or direct sunlight Position the generator on secure level ground so it wll nottip or slide down a hill Place the generator so that the exhaust fumes will not be direded 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 of 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 the cooling system
13. red and licensed electrician and in compliance with all applicable state and 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 electridan TROUBLESHOOTING Voltage too low a Engine speed too slow a Bring generatorto a qualified technidan for adjustment b Generatoris ovedoaded b Reduce the load See Load Circuit breaker trips Voltage too high Generator overheating No output voltage Belt slippage or coupler slippage Defective load connected to generator Defective receptade Generator overnoaded Engine speed too high Generator is ovetoaded Insufficient ventilation Defective load connected to generator Broken orloose wire Defective receptade Defective stator Defective rotor Defective capadtor Defective circuit breaker Belt s is slipping or broken or coupler slipping Application section of this manual c Tighten belt s or tighten coupler a Disconnectload b Replace receptacle c Reduce the load See Load Application section of this manual a Bring generator to a qualified technidan for adjustment a Reduce the load See Load Application section of this manual b Make sure there is atleast 3 feet of clearance on all sides of generator a D
14. sult in 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 screw located on the generator frame 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 are 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 GFCI 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 workng on the engine or generator this prevents accidental starting ALWAYS provide adequate ventilation Do not operate generator in any endosed or narrow space Engines consume oxygen and give off deadly carbon monoxide a poisonous gas Improper ventilation wil cause damage to generator a
15. t of use is held to aminimum Maximum Extension Cord Length Amps Load 10 12 14 at watts Ga Ga Ga 240V Cord Cord Cord 10 2400 250 150 100 75 20 4800 125 75 50 25 30 7200 60 35 25 10 40 9600 30 15 10 50 12000 15 E T i CAUTION Equipment damage can result from the low voltage caused by using an extension cord wth a small wire size Use this chart to estimate the total load on your generator For Determining Generator Load Requirements Dev ice 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 Not recommended 7 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 Freezer 800 b Furnace Fan 1 3 HP 1200 a 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
16. ting a resistive inductive load such as a fluorescent or mercury light transformers or inductive coils a capacity 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 phase motors are very hard to start and require 5 to 7 times more currentto start than to run Capadtor 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 RI 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 f the ele
17. ury ordeath 1543 Foot print of mounting feet is shown at left The user shall determine the PlUse 7 16 tensioning method for their specific use To determine belt tension asure L the center to center distance of the t 00292 sheaves M ASNTEQn tional mount Kt item 165935 is available in 00590 the Northern catalog and the NorthStar parts catalog Includes 2 plates and mounting hardware grade 5 bolts Tighten orloosen belt until dz0 016 XL If the control box is not located on the correct side for your application it can be rotated to the opposite side First remove the fan vents than remove the four drive end bracket bolts Rotate the drive end bracket 180 re torque bolts to 17 ftelb Reinstall the fan vents Remove the four screws at the base of control box rotate the control box 180 The voltmeteris now on the back of the machine instead of the front See below for terminology REMOVE SCREWS TOF AND BOTTOM DRIVE END A 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 brought in and exhausted out to ensure proper cooling of the engine and generator If you desire to direct couple the generooz93 an engine great care must be taken to align the snatt of the generator and engine to within the specified tolerances of the chosen coupler NEVER install your generator inside confin
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