North Star 5500 BDG User's Manual
Contents
1. 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 1 1 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 overoading 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 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 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 If difficulties in starting a motor are experienced turn off2. 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 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 a Paint Sprayer Airless hand held 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 unning 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 priorto shipment from the factory A factory test report has been induded with this manual 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 GROUNDING All units must be grounded Drive a 3 4 or 1 copper pipe or rod
3. hazards or death A DANGER Always have proper guarding on the V belt and sheaves to prevent access to any pinch points Failure to guard the power transmission mechanisms may result in serious injury or death Cooling air of sufficient amounts must be brought in and exhausted out to ensure proper cooling of the engine and generator A DANGER Remember exhaust fumes are deadly carbon monoxide gas and must be vented to the outside where there are no people LOAD APPLICATION It is 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 wring insulation If the generator is overloaded the wres become excessively hot and cause the insulation to break down reducng 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
4. into the ground close to the generator The pipe od must penetrate moist earth Connect an approved ground clamp to the pipe Run a 12 gauge wire from the camp 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 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 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 Weed Trimmer 500 Load 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 Freq
5. receptacles can be both dangerous to the operator and destructive to the equipment Percent of Speed Frederic Generator Generator RPM Hz voltage at 120V Output Receptade 0 3720 62 0 129V 50 3600 60 0 120V 100 3540 59 0 115V 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 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 electrid an TROUBLESHOOTING Problem Voltage too low Circuit breaker trips Voltage too high Generator overheating No output voltage Engine lacks power Possible Causes Engine speed too slow Generator is oveloaded Defective load connected to generator Defective receptade Generator overioaded Engine speed too high Generator is ovenoaded Insufficient ventilation Defective load connected to generator Broken orloose wire Defective receptade Defective stator Defective rotor Defective capacitor Generator is ovenoaded Dirty air filter Possible Remedies a Bring generator to a qualified technidan for adjustment b Reduce the l
6. 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 1 Specifications 2 Machine component identification 3 Generator features 3 4 Introduction 4 ANSI safety definitions 4 Rules for safe operation 4 5 Installation 5 6 Load application 6 7 Pre start up preparation 7 8 Generator care 8 Troubleshooting 9 Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Engine Speed 120 V Receptacle 240 V Receptacle Circuit Breaker Dimensions Length Width Height Gross Weight SPECIFICATIONS 165913 5500 Watts W 5000 Watts W 120 240 Volt V Single phase 4 wire 59 0 62 0 Hertz Hz 100 11 hp max 9 hp recommended 3540 3720 RPM 20 Amp A duplex NEMA 5 20R 20 Amp A Locking Device NEMAL6 20R 20 Amp A thermal push to reset style 16 25 413 cm 7 25 184 cm 7 75 197 cm 53 Ib 24 1 kg MACHINE COMPONENT IDENTIFICA TION Figure 1 Ref 1 4 00041 1 Circuit Breakers 5 7 8 shaft 2 120V 20A Duplex Receptacle 6 Mounting feet 3 240V 20A Locking Receptacle 7 Fan vents 4 Grounding screw Figure 2 Ref 5 7 00042 GENERATOR FEATURES Reference 1 Circuit Breakers This belt driven single phase generator has 2 20 amp A push to reset circui
7. CE A MODEL 5500 BDG ITEM 4165913 Belt Driven Generator aS Proven Performance M165913B OWNER S MANUAL A WARNING Read this manual Serious injury or death can result if safety instructions are not follawed A DANGER Fire hazard Du not operate in an enclosure or building Fire or exp asion will result Never place Ihis producl near combustible malerials A DANGER Breathing hazard Poisonous fumcs from cngine will kill you Do not operate the generator in enclosed areas Do not eperate generator near building ar inside af buildings Any Questions Comments or Problems Call Customer Service at 1 800 270 0810 THANK YOU Thank you for purchasing a North Star 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 North Star Belt Driven Generator IMPORTANT If this machine is used by anyone who isnot the owner oris loaned or rented make certain the operator Is instructed in the safe and proper operation of this machine Reads and understands the manuals pertaining to this machine NOTICE K
8. 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 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 phase 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 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
9. RNING Keep fire extinguisher close by your generator and be familiar with how to use it Consult your local fire department for correct extinguisher type INST ALLATION 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 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 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 7 8 diameter X 1 50 long with a 3 16 keyway Use the table below to select the correct diameter sheave Note that a notched V belt requires only one sheave while the standard V belt requires 2 side by side sheaves and 2 V belts All V belts have a B size cross section eae Single Sheave Dia Double Sheave Dia pee AR Belt Type Qty Belt Type Qty ei 5 00 4 60 p Notched V Belt 1 V Belt 2 PRE 5 80 5 00 p Notched V Be
10. 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 Maximum Extension Cord Length 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 i 50 12000 15 zi z Z 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 Load Requirements Device Running Watts 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 lron 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 Diill 1 1100 Hand Dill 1 2 875 Hand Dill 3 8 500 Hand Dill 1
11. arth 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 working on the engine or generator this prevents accidental starting ALWAYS provide adequate ventilation Do not operate generator in any enclosed or narrow space Engines consume oxygen and give off deadly carbon monoxide a poisonous gas Improper ventilation wil cause damage to generator and possible injury to people ALWAYS remove all oil or gasoline deposits and accumulated dirt from generator and immediate area Keep generator head and engine clean 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 Enclosed compartments or confined areas Flame or smoke J Rain snow or wet conditions K Operator non attendance ZONMULUOW A WA
12. lt 1 V Belt 2 Figure 3 00038 Note Guards are removed to show details TENSION SIDE SLACK SIDE IF TENSIGNER PULLEY IS USED PLACE DN THIS SIGE OF BELT SINGLE PULLEY I5 USED N_GONJUNGTION WITH A NOTCHED V BELT HEAVY DUTY BASE The shaft soeed of the generator must be between 3540 3720 RPM Atno load the correct speed is 3720 RPM If the engine is a 3600 RPM engine then a 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 fora possible mounting configuration The user shall determine the proper belt tensioning method for their specific use To determine belt tension Measure L the center to center distance of the two sheaves Measure d the deflection of the belt Tighten orloosen belt until d 0 016XL If you desire to direct couple the generator to the engine great care must be taken to align the shaft of the generator and engine to within the specified tolerances of the chosen coupler NEVER install your generator inside confined areas Inside installation can cause health
13. oad 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 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 Disconnectload b Bring generator to a qualified technican for repair c Replace receptacle d Bring generator to a qualified technican for repair e Bring generator to a qualified technican for repair f Bring generator to a qualified technican for repair a Reduce the load See Load Application section of this manual b Clean or replace air filter
14. omance and long life of the generator North Star is constantly improving its products The specifications 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 serious injury This signal word 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 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 e
15. t breakers to protect against electrical overloads Receptacles Reference 2 120V Receptacle The generator has an end cover 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 recepiade 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 3 240V Receptacle The locking deviceisa 240V 20A NEMA L620R receptacle This receptacle accepts a NEMA plug number L6 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 4 Ground Screw Ground the generator via the ground screw to a copper pipe or rod that is driven into moist soil Reference 5 7 8 diameter Shaft The shaft is 1 50 long and has a 3 16 keyway Reference 6 Mounting feet Use these three locations to bolt the generator head in place Reference 7 Fan Vents Never block the vent slots or insert objects through the slots 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 perf
16. uency can be checked by using an electric clock with a sweep second hand Timed against a wrist watch or a stop watch the clock should be correct within 2 seconds per minute All soeed setting adjustments should be done by a qualified technician GENERATOR CARE The 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 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 A Bearing The bearings used in this generators are a 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
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