North Star 10000 PPG User's Manual
Contents
1. 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 16 at watts Ga 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 Not recommended CAUTION Equipment damage may result from the low voltage caused by using an extension cord with a small wre size 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 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 Dail 1 2 875 Hand Dill 3 8 500 Hand Diill 1 4 250 Hedge Trimmer 450 Home Computer 150 Load Requirements continued Impact Wrench 500 Jet Pump 800 Lawn Mower 1200 Light Bulb 100 Microwa2. a 10 Ga wire from the clamp to the generator grounding screw located on the generator head 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 shutdown 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 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 generatoris loaded to its full capacity than when it is running wth no load The slight variation has no apprecable 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
3. 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 now be connected to generator STOPPING 1 Disconnect all loads to generator 2 Turn engine key switch to OFF position 3 Turn gas line valve to OFF position ENGINE CARE Refer to your Engine 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 adeflector piece of cardboard or paper to direct the oil down the hole 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 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 corrosion in 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
4. 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 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 current to start than to run Capadtor motors are easier to start and usually require 2 to 4 times as much current to start as to run Repulsion Induction motors are the easiest to start and require 1 5 to 2 5 times as much to start asto tun 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 Watts 1 6 525 7 11 9 18 16 22 1 4 700 9 15 12 23 22 32 1 3 875 1
5. into its cooling system NEVER install your generator inside confined areas Inside installation can cause health hazards or death DANGER Remember exhaust fumes are deadly carbon monoxide gas and must be vented to the outside where there are no people Cooling air of sufficient amounts must be allowed to flow in and exhausted out to ensure proper cooling of the engine and generator head LOAD APPLICATION Itis 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 If wattage is not given on equipment nameplate approximate wattage may
6. 1 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 alight load such as a power saw it will require less starting current The exact requirement will also vary with the brand ordesign 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 ina short time The generatorhead winding might also be damaged Running the generator under these conditions may result in damage to the generator stator as well as the motor windings Because the heavy surge of current is required foronly an instant the generator will not be damaged if it can bring the motor up to speed in a few seconds If difficulties in starting a motor are experenced turn off all other electrical loads and if possible reduce the load on the electric motor EXTENSION CORDS
7. 30P lug Halarenice 6 120V Locking Receptacle This locking receptade is a 120V 30A NEMA L5 30R receptacle This receptacle accepts a NEMA L5 30P lug j Raiorenies 7 120V Receptacle The generator hasa control panel with two duplex two receptacles in a common housing receptades Each duplexis a 120 volt V 20 amp A straight blade receptacle National Electrical Manufacturers Association NEMA number 5 20R This receptade accepts NEMA plug numbers 5 15P and 5 20P Each duplex is capable of drawing 20A at 120V 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 wite electrical plugs and or cordsets Improper wiring could result ina fire or electrical shock Reference 8 Oil Drain Plug Refer to your Vanguard engine manual for oil change recommendations Reference 9 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 10 Wheel Kit Heavy duty wheel kit Item 165919 Reference 11 10 0 Gallon Gas Tank Large tank allows for extended run capabilities Always allow room for gasoline expansion by not filling the gas tank completely Reference 12 Recoil Optional staring method G
8. CE 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 1 Spedifications 2 Machine component identificati on 3 Generator features 4 Introduction 5 ANSI safety definitions 5 Rules for safe operation 5 Installation 6 Load application 6 7 Pre start up preparation 7 8 Starting 8 Stopping 8 Engine care 8 Generator care 8 9 Troubleshooting 10 SPECIFICATIONS Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Total Hamonic Distortion Engine Engine Speed Fuel Type Fuel Capacity Oil Capacity Starting Method 120 V Receptades 120 240 V Receptacle Circuit Breakers Battery Dimensions Length Width Height Dry Weight 165967 10000 Watts W 8500 Watts W 120 240 Volt V Single phase 4 wire 56 5 63 3 Hertz Hz 1 0 p f less than 5 18 HP Honda 3390 3798 RPM Unleaded gasoline 10 gallons 38 0 L 1 6 US quarts Electric start Recoil 2 20 Amp A duplex NEMA 5 20R 30 Amp A locking receptacle NEMA L5 30R 30 Amp A locking receptacle NEMA L14 30R 50 Amp A straight blade NEMA 14 50R 40 Amp A thermal magnetic 30 Amp A thermal magnetic 30 Amp A thermal push to reset 2 20 Amp A themal push to reset 12 VDC 18 Amp Hour minim
9. Load Output Sd Percent of Speed Frequency Generator Generator RPM Hz Voltage at 120V Output Receptacle 0 3750 62 5 129V 50 3600 60 0 120V 100 3540 59 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 clock with a sweep second hand Timed against a wristwatch or a stopwatch the clock should be correct within 2 seconds per minute All speed setting adjustments should be done by a qualified technician BEFORE STARTING 1 Make sure the generator is positioned on firm level surface 2 Check the crankcase for oil and maintain at a proper level 3 Check fuel level and fill tank 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 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
10. Maintenance The generator head is brushless and maintenance free Any major generator service including the installation or replacement of parts should be perfomed by a qualified electrical service technican USE ONLY FACTORY APPROVED REPAIR PARTS Obtain factory parts from Customer Service at 1 800 270 0810 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 Fire Departments must be consulted concerning proper and safe handling procedures for gasoline NEVER connect any generator to any existing electrical system without an isolating UL approved transfer switch installed by a licensed electrician TROUBLESHOOTING Problem Engine wil not start Voltage too low Circuit breaker trips Voltage too high Generator overheating No output voltage Engine lacks power Engine shuts down during operation Possible Causes Low oil lev
11. Tia MODEL 10000 PPG ITEM 165967 Professional Portable Generator Proven Performance M165967A A WARNING Read this manual Serious injury or death can result if safety instructions are not followed A DANGER Fire hazard Do not operate in an enclosure or building Fire or explosion will result Never place his producl near combustible rnalerials A DANGER Breathing hazard Poisonous fumes from engine will kill you Do not operate the generator in enclosed areas Do not operate generator near building or inside of buildings OWNER S MANUAL Any Questions Comments or Problems Call Customer Service at 1 800 270 0810 Hours Monday Friday 7 00 AM to 5 30 PM CST Saturdays 7 30 AM to 11 30 AM CST 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 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 Pro 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 NOTI
12. bilities 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 head 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 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 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 generatorhead and engine clean NEVER operate the
13. e air filter a Fill fuel tank b Fill crankcase to proper oil level
14. el 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 10 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 section of this manual b Clean or replac
15. 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 Rain snow or wet conditions Operator non attendance A TTOMmNmMvoOwW 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 WARNING Keep fire extinguisher dose to 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 will nottip or slide down a hill Place the generator so that the exhaust fumes will not be directed towards people The installation site must be free from water moisture or dust All electrical components should be protected from excessive moisture or the insulation system will deteriorate and result in grounding or shorting out the generating system Foreign matters such as dust dirt sand lint or abrasive materials can cause damage to the generator head and engine if allowed
16. rasp firmly when starting engine Reference 13 Muffler and Spark Arrestor Reference 14 Oil Filter Reference 15 Battery Box Warning Always wear safety glasses when working on or near the battery The battery box provides protection for the battery and wil accept the standard lawn tractor size battery Group U1 7 The engine requires a 12 volts dc battery with a minimum rating of 18 Amp Hours When installing the battery always connect the red colored positive or cable first When disconnecting the battery always remove the black colored negative or cable first A WARNING Sulfuric acid is a corrosive poison Avoid contact wth skin eyes or dothing Always wear safety glasses Reference 16 Gas Line Valve The generator tank has an ON OFF valve mounted underneath the tank Always keep this valve closed when the generator is notin use Reference 17 Generator Head The electricity producing part of the generator Reference 18 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 Low Oil Shutdown The Honda engine is protected against damage resulting from low engine oil Always check your oil level daily INTRODUCTION Before starting your generator thoroughly study the instructions and cautions in this manual to a
17. ssure 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 Vanguard engine owners manual furnished with the generator Briggs and Stratton refer to the 18 HP engine asa 350447 NorthStar is constantly improving its products The spedficatons 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 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 resultin minor or moderate injury It may also be used to alert against unsafe practices RULES FOR SAFE OPERATIONS Safety precautions are essential when operating this generator Respectful and cautious operation wil considerably lessen the possi
18. um Group Size U1 7 35 75 90 8 an 24 25 61 6 an 26 25 66 7 an 320 Ib 136 MACHINE COMPONENT IDENTIFICATION FRD1625 Ref Air Cleaner 11 10 0 Gallon Gas Tank Grounding Screw 12 Recoil 120 240V 50A Receptacle 14 Oil Filter 15 Battery Box 16 Gas Line Valve 17 Generator Head 18 Gas Cap with Gauge 120V 30A Locking Rec 120V 20A Duplex Rec Oil Drain Plug 9 Vibration Isolation Mount 10 Wheel Kit 165919 Circuit Breakers 13 Muffler amp Spark Arrestor 1 2 3 4 5 120 240V 30A Locking Rec 6 7 8 GENERATOR FEATURES Reference 1 Air Cleaner Refer to your Honda Engine Owners Manual for air cleaner care Reference 2 Grounding Screw Ground the generator via the grounding screw to a copper pipe or rod that is driven into moist soil Reference 3 Circuit Breakers This portable single phase generator has 1 40 amp A thermal magnetic 2 pole breaker 1 30 amp A thermal magnetic 2 pole breaker 1 30 amp A push to reset circuit breaker and 2 20 amp A push to reset circuit breakers Circuit breakers protect against electrical overloads Reference 4 120 240V Receptacle This receptacle is a 120 240V 50A NEMA _ 14 50R receptacle This receptacle accepts a NEMA 14 50P plug Use this receptacle if installing a transfer switch Reference 5 120 240V Locking Receptacle This Locking is a 120 240V 30A NEMA L14 30R receptacle This receptacle accepts a NEMA L14
19. ve 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 Hir 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 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 unning watts b These loads may require up to 15 minutes to restart due to their normal 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 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 machine The pipe rod must penetrate moist earth Connect an approved ground clamp to the pipe Run
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