North Star 5500 IPG User's Manual
Contents
1. MODEL 5500 IPG ITEM 165926 Industrial Portable Generator M165926A 5500 IPG 00219 Shown with Optional Wheel Kit Item 165916 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 CST THANK YOU Thank you for purchasing a North Star Industrial Portable 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 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 North Star Industrial Series 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 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 pr2. 2 Check the crankcase for oil and maintain at a proper level 3 Check fuel level and fill tank with fresh unleaded gasoline Never fill 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 MANUAL 1 Disconnect all loads to generator 2 Tum gas line valve to ON position 3 Tum key to the 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 Firmly grasp recoil handle and pull 6 When engine starts move choke lever to RUN position 7 Loads may now be connected to generator STARTING ELECTRIC 1 Disconnect all loads to generator 2 Tum gas line valve to ON position 3 For cold engine move choke lever to full choke position for warm engine move choke lever to half choke or to RUN position 4 Tum key to start position 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 Place key to the 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 Use a deflector piece of cardboard or paper to direct the oil down the hole
3. Reference 17 Voltmeter Voltmeter needle should be in green area during all generator load conditions Reference 18 Full Power Switch The switch reconnects the two generator windings from parallel 120V only to series 120 240V e 120V Only Allows all 4500 watts 87 5A to be used in any combination of 120 volt receptacles The 120 240V receptade is disabled e 120 240V_ Allows all 4500 watts to be used for 240V However only half the power or 2250 watts 18 8A can be used at any one 120V receptade 120V output can total 4500 watts Reference 19 Idle Control On Off Switch This feature senses the load on the generator With no load on the generator the engine speed drops to idle This saves fuel and lengthens engine life When a load is applied the engine speed returns to 3600 RPM nominal Turning the switch off disables the sensing device and the generator will run at 3600 3780 RPM whether or not a load is applied Reference 20 Adjustable Idle Delay Adjusts the amount of time from when the generator senses there is no load to when the generator actually idles down The minimum delay is 5 seconds The maximum is approximately 1 minute Reference 21 120 240V 20A Receptacle One twistlock 120 240V receptacle capable of drawing 20 amps NEMA number L14 20R This receptade accepts only NEMA 14 20P plugs one of which is shipped with the generator Use this receptacle if installing a transfer switch Compatible with Ge
4. 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 result 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 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 warnne 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 orhandle any electrical equipment while standing in water while barefoot while hands are wetor 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
5. as a standby electric power source in case of utility failure it must be installed by a registered and licensed electridan 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 Problem Engine wil not start Voltage too low Circuit breaker trips Voltage too high Generator overheating No output voltage Engine lacks power Idle control doesn t work Engine shuts off during operation Possible Causes Low oil level Fouled spark plug Out of fuel Stop switch in OFF position Battery has lost its charge a Engine speed too slow b Generatoris ovedoaded c Idle control is malfunctioning b Defective receptade Generator overoaded a Engine speed too high a Generatoris ovedoaded b Insufficient ventilation a Defective load connected to generator b Broken orloose wire c Defective receptade d Defective stator e Defective rotor f Defective capacitor a Generatoris ovendoaded b Dirty air filter a Switch isin OFF position b Solenoid failure c Defective circuit board d Defective capacitor e Circuit breaker tripped a Outof fuel b Low oil level
6. 0A magnetic 2 pole main circuit breaker to protect against electrical overloads Reference 29 Hour Meter Allows for a better maintenance schedule of 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 stop switch remains in the on position The engine will not start until 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 will result in operator safety best perfomance and long life of the generator For detailed engine operation and maintenance always refer to the Honda engine owners manual furnished with the generator Honda refers to the 9 HP engine as a GX270 North Star 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 alteratons 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
7. 10 Defective load connected to generator Possible Remedies a Fill crankcase to proper oil level b Clean or replace spark plug c Fill fuel tank d Place switch in ON position e Battery has low electrolyte and or needs to be charged or replaced a Bring generator to a qualified technican for adjustment b Reduce the load See Load Application section of this manual c Bring generator to a qualified technican forinspection a Disconnectload b Replace receptacle c Reduce the load See Load Application section of this manual a Bring generator to a qualified technican 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 generator to a qualified technician for repair c Replace receptacle d Bring generator to a qualified technician for repair e Bring generator to a qualified technician 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 Place switch in ON positon b Check for24VDC at solenoid Check coil resistance it should be 73 90 5 Check for sticking in mechanism and solenoid Replace idle assembly if necessary c Bring generator to a qualified technician for repair d Bring generatorto a qualified technician for repair
8. GENERATOR CARE The generator head is a two pole 3600 RPM 60 Hz brushless revolving field and synchronous type with one sealed ball bearing The rotor of the generator head is directly connected 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 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 corrosion in the winding Frequent operation of the engine generator will also ensure that the set is operating propery 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 technician USE ONLY NORTHSTAR APPROVED REPAIR PARTS AVAILABLE AT 1 800 270 0810 A Bearing The bearing usedin 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 receptades can be both dangerous to the operator and destructive to the equipment A WARNING Stand by Operation If your generator is to be used
9. ON 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 electical 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 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 outto ensure proper cooling of the engine and generator head LOAD APPLICATION It is important to determine the total electrical load before it is 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 generatoris overloaded the wres become excessively hot and cause the insulation to break down redudng its ab
10. ad Requirements 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 Freezer 800 b Furnace Fan 1 3 HP 1200 a Hair Dryer 1200 Hand Diill 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 Load Requirements Continued 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 Pump 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
11. c Stop Start Switch Figure 2 Ref 8 16 00230 3 GENERATOR FEATURES Reference 1 Air Cleaner Refer to your Honda engine manual for air deaner care Reference 2 Starting Stopping Instructions Reference 3 Oil Drain Plug Refer to your Honda engine manual for oil change recommendations Reference 4 Control Panel See Fig 3 for details Reference 5 Gas Cap with Gauge The gas cap is extra large creating a large hole for refilling and a comfortable grip You can always monitor the fuel level without removing the cap by using the fuel level indicator builtinto the gas cap Reference 6 6 5 Gallon Gas Tank Large tank allows for extended run capabilities ALWAYS allow room for gasoline expansion by not filling the gas tank completely full Reference 7 Super Silent Muffler 8 dB less than Honda s standard muffler NEVER operate generator without the exhaust deflector attached in the upright position Reference 8 Gas Drain Valve The generator is equipped wth a unique feature A gas drain valve is installed to drain gasoline from the tank without disconnecting the gas line feeding the engine This valve is intended to be used to drain gas prior to extended periods of non use Itis recommended that if the period of non use is longer than 30 days the gas should be drained andthe engine ran until all the gas is evacuated from the carburetor ALWAYS make sure this valve is closed prior to filling the gas tank Refer
12. e Reset circuit breaker a Fill fuel tank b Fill crankcase to proper oil level
13. ence 9 Gas Line Valve The generator tank has an ON OFF valve mounted underneath the tank ALWAYS keep this valve closed when the generator is not in use or being transported Reference 10 Generator Head The electridty producing part of the generator Reference 11 Battery and Box The power source for electric starter Reference 12 Vibration Isolation Mounts The engine and generator head are mounted on rubber cylinders that absorb most of the engine vibration This feature eliminates the tendency of the machine to walk which is common in engine powered equipment Reference 13 Recoil Grasp firmly when starting engine Reference 14 Fuel Valve Lever Additional valve for fuel shut off Reference 15 Choke Lever Used during cold starts Refer to the starting stopping instructions and the Honda engine manual for usage Reference 16 Electric StartStop Switch The engine key is located on the engine Always locate this switch and be familiar with its location before operating the generator CONTROL PANEL IDENTIFICATION Figure 3 Ref 17 29 00242 Description 17 Voltmeter 18 Full Power Switch 19 Idle Control On Off Switch 20 Adjustable Idle Delay 21 120 240V 20A Twistlock Receptacle 22 Grounding Post 120V 30A Twistlock Receptade 24 120V 50A Straight Blade Receptacle 25 120V 20A GFCI Duplex Receptade 26 30A Circuit Breaker 27 20A Circuit Breaker 28 Main Line Circuit Breaker 20A 29 Hour Meter
14. eparation Starting Manual Starting Electric Stopping Engine care Generator care Troubleshooting SPECIFICATIONS ltem Number 165926 Maximum Output 5500 Watts W Continuous Output 4500 Watts W Voltage 120 240 Volt V Phase Single phase 4 wire Frequency 58 0 63 0 Hertz Hz Power Factor 1 0 p f Engine 9 HP Honda GX270 Engine Speed 3480 3780 RPM Fuel Type Unleaded gasoline Fuel Capacity 6 5 gallons 24 6 L Oil Capacity 1 16 US quarts 1 1 L Starting Method Electric Start Recoil 120 V Receptacle 2 20 Amp A duplex GFCI NEMA 5 20R 1 30 Amp A twistlock NEMA L5 30R 1 50 Amp A Straight Blade NEMA 5 50R 120 240 V Receptacle 20 Amp A twistlock NEMA L14 20R Circuit Breaker 2 20 Amp A Thermal push to reset 1 30 Amp A Thermal push to reset 1 20 Amp A Magnetic 2 Pole Grounding Post Receives 10 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 195 Ib 88 6 kg Gross Weight 240 Ib 109 k MACHINE COMPONENT IDENTIFICATION Figure 1 Ref 1 7 00229 Ref 1 Air Cleaner 9 Gas Line Valve 2 Starting Stopping Instructions 10 Generator Head 3 Oil Drain Plug 11 Battery amp Box 4 Control Panel 12 Vibration Isolation Mount 5 Gas Cap with Gauge 13 Recoil 6 6 5 Gallon Gas Tank 14 Fuel Valve Lever 7 Super Silent Muffler 15 Choke Lever 8 Gas Drain Valve 16 Electri
15. ility 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 determined 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 electiic power tools a capacity of up to the generator full rated wattage output can be used When connecting a resistive inductive load such asa 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 un Some motors particularly low cost split phase motors are very hard to start and require 5 to 7 times more current to start than to run Capacit
16. ntran transfer switch item 16411 Reference 22 Grounding Post Ground the generator via the grounding post to a copper pipe or rod that is driven down until it reaches moist soil References 23 25 120V Receptacles The generator has a control panel with e Reference 23 two duplex two receptacles in a common housing 120V GFCI straight blade receptacles capable of drawing 20 amp National Electrical Manufacturer s Association NEMA part number 5 20R These receptades accept NEMA numbers 5 15P or5 20P plugs e Reference 24 one straight blade 120V receptacle capable of drawing 50 amp NEMA 5 50R This accepts only NEMA 550P plugs one of which is shipped with the generator e Reference 25 one twistlock 120V receptacle capable of drawing 30 amps NEMA number L5 30R This receptade accepts only NEMA number 5 30P plugs one of which is shipped 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 A WARNING Contact a licensed electrician to wire electrical plugs and or cordsets Improper witing could result in a fire or electrical shock Never use defective or broken plugs or receptades References 26 28 Circuit Breakers This portable single phase generator has e Reference 26 2 20 amp A push to reset circuit breakers e Reference 27 1 30A push to reset circuit breaker e Reference 28 1 2
17. or motors are easier to start and usually require 2 to 4 times as much current to start than to tun 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 asa blowerorfan 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 overloading differently than the power line When overloaded the engine is not able to supply enough power to bring the electric motor up to operating soeed The generator responds to
18. the high initial starting current but the engine speed diops sharply The overload may stall the engine If allowed to operate at very low speeds the electric motor starting winding will burn out in a short time The generator head 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 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 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 i Load gt A 14 watts Ga Ga Rn gt ee Cord Cord 10 75 20 j 2400 250 150 100 4800 125 75 i 30 7200 60 35 25 10 40 9600 30 15 10 7 50 12000 15 i i Not recommended CAUTION Equipment damage can result from the low voltage caused by using an extension cord with a small wire size Use this chart to estimate the total load on your generator For Determining Generator Lo
19. tor 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 slowdown 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 generator is loaded to its full capacity than when it is running with 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 Percent of Speed TE Generator Generator RPM Hz Voltage at 120V Suipi Receptade 3780 63 0 129V i 3600 60 0 120V 100 3480 58 0 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 dock with a sweep second hand Timed against a wist watch ora stop watch the dock should be correct within 2 seconds per minute All soeed setting adjustments should be done by a qualified technician BEFORE STARTING 1 Make sure the generator is positioned on firm level surface
20. 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 included with 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 Runa no 10 Ga wire from the clamp to the generator grounding post located on the control panel Do not connect to a water pipe or a 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 at the factory so that the generator produces the proper voltage and frequency The output voltage should be checked to ensure the genera
21. wire before working on the engine or generator to prevent 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 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 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 Excessive ovedoad of generator Wire with too small a gauge for the load gt Z r xAc TOMmMmMoIoOD 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 INSTALLATI
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