North Star 5500 User's Manual
Contents
1. b Freezer 800 c Hair Dryer 1200 Hand Drill 1 1100 Hand Drill 1 2 875 Hand Drill 3 8 500 Hand Drill 1 4 250 For Determining Generator Load Requirements Hedge Trimmer 450 Home Computer 150 a Impact Wrench 500 Jet Pump 800 b Lawn Mower 1200 Light Bulb 100 Microwave Oven 700 Milk Cooler 1100 b Oil Burner on Furnace 300 Oil Fred Space Htr 140 000 Btu 400 Oil Fired Space Htr 85 000 Btu 225 Oil Fred Space Htr 30 000 Btu 150 Oven 4500 Paint Sprayer Airless 1 3 HP 600 b Paint Sprayer Airless handheld 150 Radio 200 a Refrigerator 600 c Slow Cooker 200 Submersible Pump 1 1 2 HP 2800 b Submersible Pump 1 HP 2000 b Submersible Pump 1 2 HP 1500 b Sump Pump 600 b Table Saw 10 2000 b Television 500 a Toaster 1000 Vacuum cleaner 250 VCR 70 a Water Heater 3000 Weed Trimmer 500 a Always use a voltage surge protector between the generator and these voltage sensitive loads To order a surge protector call customer service at 1 800 270 0810 and ask for item 30793 b Hard starting motors require 3 to 5 times the rated running watts c These loads may requite 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 ge2. generator will also ensure that the setis operating properly should it be needed in an emergency Generator Maintenance The generator head is brushless and maintenance free Major generator service induding installation or replacement of parts should be performed only by a qualified electrical service technican USE ONLY FACTORY APPROVED REPAIR PARTS A Bearing The bearing used in these generators isa heavy duty sealed roller 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 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 registered and licensed electrician and in compliance with all applicable state and local electrical codes Also local Are 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 electidan 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 durin
3. 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 A 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 Endosed compartments or confined areas Flame or smoke Rain snow or wet conditions Operator non attendance ACU rommIv0OD A WARNING Check fuel 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 A 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 a location where the generator will not be exposed to rain snow or direct sunlight Position the generator on secure level ground so it will not tip or side 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
4. stop switch remains in the on position The engine will not start untl the oil is refilled to above the safe level 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 Honda engine owner s manual furnished with the generator Honda refers to the 8 Hp engine as a GX240 NorthStar is constantly improving its products The specificatons outlined herein are subject to change without prior 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 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 result in minor or moderate injury It m
5. 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 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 allowed to flow in and exhausted out to ensure proper cooling of the engine and generator head 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 can attack the witing 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 te
6. winding will bum out ina short time The generator head winding might also be damaged Running the generator under these conditons may result in damage to the generator stator as well as the 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 If difficulties in starting a motor are experienced turn off all other electrical loads and if possible reduce the load on the electtic 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 Maximum Extension Cord Length 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 Dev ice Running Watts Air Conditioner 12 000 Btu 1700 b 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 b Compressor 3 4 HP 1800 b Compressor 1 2 HP 1400 b 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
7. Tie MODEL 5500 PPG ITEM 165950 Professional Portable Generator A N Proven Performance M165950A OWNER S MANUAL A WARNING Read this manual Serious injury or death can result if safety instructions are nat followed A DANGER Fire hazard Do not operate in an enclosure or build rg Fire ar explosion will result Never place this product near combtu sible materials ADANGER Breathing hazard Poisonous fumes from engine will kil you De nel operale the gencralor in enclosed areas De nol operale gencralor near building or rside of buildings Call Customer Service at 1 800 270 0810 THANK YOU Thank you for purchasing a NorthStar Pro Series 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 machines 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 Pro Series Generator IMPORTANT If this machine is used by anyone who isnot the owner oris loaned or rented make certain the operator Is instructed in safe and proper operation of this machine Reads and understands the manuals pertaining to this machine NOTICE K BAR Industries Incorporated reserves th
8. ay also be used to alert against unsafe practices RULES FOR SAFE OPERATIONS Safety precautions are essential when operating this generator Respectful and cautious operaton will 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 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 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
9. e right to make improvements in design and or changes in specifications 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 SPECIFICATIONS Item Number 165950 Maximum Output 5500 Watts W Continuous Output 4000 Watts W Voltage 120 240 Volt V Phase Single phase 4 wire Frequency 56 5 63 3 Hertz Hz Power Factor 100 Engine 8 Hp Honda GX240 Engine Speed 3390 3798 RPM Fuel Type Non leaded automobile gasoline Fuel Capacity 6 5 gallons 24 6 L Oil Capacity 1 16 US quarts 1 1 L Starting Method Recoil 120 V Receptacle 20 Amp A duplex NEMA 5 20R 20 Amp A locking device NEMAL14 20R 120 240 V Receptacle 20 Amp A locking device NEMAL14 20R Circuit Breaker 20 Amp A thermal push to reset Grounding Post Receives 12 Ga wire or fork terminal Dimensions Length 31 75 80 6 cm Width 23 63 60 0 cm Height 22 25 56 5 cm Dry Weight 180 Ib 82 kg Gross Weight 220 Ib 100 k MACHINE COMPONENT IDENTIFICATION Figure 1 Ref 1 9 00581 Ref 1 Circuit Breakers 9 Super Silent Muffler 2 120 240V 20A 10 Gas Cap with Gauge Locking device Rec 3 Groundin
10. engine Always locate this switch and be familiar with its location before operating the generator Reference 7 Decal Reference 8 Air Cleaner Refer to your Honda engine manual for air deaner care Reference 9 Super Silent Muffler 8 dB less than Honda s standard muffler Reference 10 Gas Capwith Gauge The gas cap is extra large creating alarge hole for refilling and a comfortable grip You can always monitor the fuel level without removing the cap by using the fuel level indicator built into the gas cap Reference 11 6 5 Gallon Gas Tank Large tank allows for extended run capabilites Always allow room for gasoline expansion by not filling the gas tank completely full Reference 12 Generator Head The electidty producing part of the generator Reference 13 Vibration Isolation Mounts The engine and generator head are mounted on rubber cylinders that absorb most of the engine vibration Reference 14 Recoil Grasp fimly when starting engine Reference 15 Choke Lever Used during cold starts Refer to the Honda engine manual for usage Reference 16 Fuel Valve Lever The Honda engine has an ON OFF valve Always keep this valve closed when the generator is not in use Always keep this valve closed while transporting the generator Low Oil Shutdown The Honda engine is protected against damage resulting from low oil level As the oil falls below the safe level the engine automatically shuts off the engine
11. ent 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 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 6 Amps Load 10 12 14 at watts Ga Ga Ga 240V Cord 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 j the engine If allowed to operate at very low speeds the electric motor starting
12. g Post 11 6 5 Gal Gas Tank 4 120V 20A Duplex Rec 12 Generator Head 5 Oil Drain Plug 13 Vibration Isolation Mount 6 Engine Stop Switch 14 Recoil 7 Warning Decal 15 Choke Lever 8 Air Cleaner 16 Fuel Valve Lever Figure 2 Ref 10 16 01795 3 GENERATOR FEATURES Reference 1 Circuit Breakers This portable single phase generator has 2 20 amp A push to reset circuit breakers to protect against electrical overloads Reference 2 120 240V Receptacle The locking device isa 120 240V 20A NEMA L1420R receptacle This receptacle accepts a NEMA plug number L14 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 3 Grounding Post Ground the generator via the grounding post to a copper pipe or rod that is driven into moist soil Reference 4 120V Receptacle The generator has a control panel with one duplex two receptades in a common housing receptade and one locking device receptacle The duplex is a 120 volt V 20 amp A straight blade receptacde National Electrical Manufacturers Association NEMA number 5 20R This receptacle accepts NEMA plug numbers 5 15P and 5 20P Each receptacle on the duplex is capable of drawing 20A Reference 5 Oil Drain Plug Refer to your Honda engine manual for oil change recommendations Reference 6 Engine Stop Switch The red engine stop switch is located on the
13. g 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 qualified 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 sect
14. ion of this manual b Clean or replace air filter a Fill fuel tank b Fill crankcase to proper oil level
15. 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 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 Load Output Si Percent of Speed Frequency Generator Generator RPM Hz Voltage at 120V Output Receptade 0 3750 62 5 129V 50 3600 60 0 120V 100 3540 59 0 112V Output voltage should be periodically checked to ensure continued proper operation of the generating plant and appliances it can be checked with a portable meter Frequency can be checked using an electric clock with a sweep second hand Timed against a wristwatch or a stopwatch the clock should be correct within 2 seconds per minute Engine speed 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 7 8 full with fresh unleaded automotive gasoline Never fill fuel tank completely to the top Always wipe up and remove any spilled gasoline 4 Make sure
16. n 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 amperage nameplate voltage by nameplate 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 capadty 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 curr
17. nerator 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 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
18. that the exhaust fumes are directed away from people STARTING 1 Disconnect all loads to generator 2 Turn gas line valve to ON position 3 Turn engine on off switch located on engine to ON position 4 For cold engine move choke lever to full choke position for warm engine move choke lever to half choke or to RUN position 5 Grasp recoil handle and pull 6 When engine starts move choke lever to RUN position 7 Loads may nowbe connected to generator STOPPING 1 Disconnect all loads to generator 2 Place engine on off switch to OFF position 3 Turn gas line valve to OFF position ENGINE CARE Refer to your Honda Owners Manual for proper care and maintenance NOTE When changing the oil on a hot engine the oil might overshoot the oil drain hole on the generator base 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 connected to the engine crankshaft and the stator is rigidly coupled to the engine casting via the generator head casting Exercising the Generator The generator should be operated every three to four weeks Warm the generator 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 corrosion in the winding Frequent operation of the engine
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