M165915F.1 ITEM NUMBER: 165915 SERIAL NUMBER: _____________ ® Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable Outdoor Use-Only, Belt-Driven Generator 2,600 Watt Continuous (2,900 Watt Surge) Capacity Can be used to power individual appliances plugged directly into the generator’s outlets, or as a back-up connection to a building’s power supply (via a professionally installed UL-approved transfer switch).
Hazard Signal Word Definitions 2
Table of Contents Hazard Signal Word Definitions ................................................................................................. 2 About Your Generator ................................................................................................................. 4 Specifications ................................................................................................................................. 6 Safety Label Locations ........................................................
About Your Generator Thank you for purchasing your NorthStar belt-driven generator! About Your Generator This belt-driven, portable generator is designed to provide up to 2600 Watts of electrical power (2600 watts continuous, 2900 watts Surge). Powered by an external engine, this generator can supply power: 1. As a portable power source. You can plug appliances directly into the generator’s electrical outlets. 2. As a back-up, standby power source for a building.
About Your Generator (cont’d) You must follow all instructions and safety precautions presented throughout this manual. A summary of important safety information can be found at the end of the manual. Keep this manual for reference and review. Proper preparation, operation, and maintenance will result in operator safety as well as best performance and long life of the generator.
Specifications – Item #165915 SPECIFICATIONS Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Minimum Recommended Engine Engine Speed Drive Shaft 120 V Receptacle 240 V Receptacle Circuit Breaker Dimensions Length Width Height Gross Weight #165915 2900 Watts (W) 2600 Watts (W) 120 / 240 Volt (V) Single phase (4-wire) 58.0-63.0 Hertz (Hz) 1.0 p.f. 5 Hp 3480-3780 RPM 1.
Safety Label Locations – Item #165915
Machine Component Identification - Item #165915F.1 Figure 1 (Ref. 1-3) Ref. 1 2 3 4 Description Circuit Breakers 240V 15A Duplex Receptacle 120V 15A Duplex Receptacle Grounding screw Ref. 5 6 7 Figure 2 (Ref.
Machine Component Identification – Item #165915F.1 (cont’d) REFERENCE GUIDE Reference 1 – Circuit Breakers This belt driven single-phase generator has 2, 11 amp (A) push to reset circuit breakers to protect against electrical overloads. Reference 2 – 240V Receptacle The duplex on the left is a 240V 15A NEMA 615R receptacle. This receptacle accepts a NEMA plug number 6-15P. Reference 3 –120V Receptacle The generator has an end cover with two duplexes (two receptacles in a common housing).
Power Load Planning & Management WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering. Before using your generator, determine the running and starting wattage requirements of all the electrical devices you will be powering simultaneously.
Power Load Planning & Management (cont’d) Device Electric range (1 element) Electric skillet Furnace fan (1/3 HP) Freezer Hair dryer Hand drill (1”) Hand drill (1/2”) Hand drill (3/8”) Hand drill (1/4”) Hedge trimmer Home computer Impact wrench Running Watts 1500 1250 1200 (a) 800 (b) 1200 1100 875 500 250 450 150 500 Device Refrigerator Slow cooker Submersible pump (1-1/2 HP) Submersible pump (1 HP) Submersible pump (1/2 HP) Sump pump Table saw Television Toaster Vacuum cleaner VCR Water Heater Weed trim
Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: 1. 2. 3. 4. 5. 6. Steps for Installation / Initial Set-Up Unpacking & delivery inspection. Planning the power load to stay within the generator’s rated capacity. Setting up for the type of power generation you need: a. portable power source, or b. connected to a building as a back-up power source. Selecting a site for using the generator.
Installation / Initial Set-Up 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to 2600W of continuous electrical power. It can supply electricity in two ways: 1. As a back up, standby power source for a building. For this application, you must arrange for a licensed electrician to connect the generator to your building’s electrical system via the installation of an UL-approved transfer switch.
Installation / Initial Set-Up In addition to isolating your generator from the utility system, the transfer switch connects your generator to a limited set of circuits in your building that have been chosen as critical to operate during a power outage. This generator can power up to 2,600 watts, which may not power your entire home or farm outbuilding -- you must work with the installing electrician to determine which devices/appliances you wish to power during an outage.
Installation / Initial Set-Up Make sure you plug each electrical device/appliance into the correct generator outlet based on the device’s plug configuration and voltage/amperage rating. Never exceed the amperage rating of an outlet. Extension cords may be used to power devices that are located at a distance from the generator. However, use only UL-listed, outdoor-rated, grounded extension cords of the proper size.
Installation / Initial Set-Up 4. Select a Suitable Site Before using the generator, you must select a suitable OUTDOOR location for installation and operation of your generator. The location should meet all the criteria listed below. WARNING: You must choose a suitable site for operating your generator to avoid equipment damage and/or injury and possible death from carbon monoxide poisoning, electric shock, or fire. Choose a site that meets all of the criteria specified below.
Installation / Initial Set-Up Hot engine exhaust clearance No wet conditions Do not run the generator in close proximity to other heat-generating equipment, such as another generator. The combined heat that is generated may raise air temperature in the immediate area and there will not be adequate cooling ventilation. Do not allow debris to accumulate and block airflow. Do not operate with a tarp, blanket, or cover surrounding the generator.
Installation / Initial Set-Up 5. Mount & Connect Generator and Engine You will need to supply a minimum 5 HP engine to power the generator. There are two methods to connect the generator to the engine: 1. The recommended method is to use sheaves (pulleys) and a V-belt(s). 2. An alternative method is to direct couple the generator to the engine. However this method requires great care to align the shafts of the generator and engine to within the specified tolerances of the chosen coupler.
Installation / Initial Set-Up 2. See below for a possible mounting configuration. Note: Guards are removed to show details. 3. Bolt the generator to the mounting base using three, 5/16” grade 8 bolts. See below. Mounting Holes Connect generator to engine Connect the generator to the engine using sheaves (pulleys) and V-Belt(s): 1. Select the correct sheaves and belts for this application. The generator shaft is 7/8” diameter x 1.5” long with a 3/16” keyway.
Installation / Initial Set-Up The shaft speed of the generator must run between 3540-3780 RPM. At no load, the correct speed is 3780 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.
Installation / Initial Set-Up Note: A guard has not been supplied with the generator because the manufacturer does not know the size and dimensions of the engine to be used, nor in what configuration the customer will choose to mount the generator & engine. DANGER: All parts of the power transmission assembly must be equipped with a guard that prevents access to rotating parts. Clothing or hair can become rapidly entangled in unguarded rotating parts, resulting in serious injury or death.
Installation / Initial Set-Up 6. Ground the generator Always ensure the generator is properly grounded to prevent electrical shock. You must always ground the generator by the following method when using the generator as a portable electrical source: 1) Drive a ¾” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth – the depth required will be dictated by local soil conditions. Consult with an electrician. 2) Connect an approved ground clamp to the pipe.
Operation Once you have set up your generator for use, it is time to start your generator. The following are the procedures necessary for safe, successful operation of your generator. 1. 2. 3. 4. 5. 6. Operation Procedures General Safety Rules for Operation Preparing for Operation (Pre-start checklist) Starting the Generator Connecting Loads Stopping Storage & Exercise Each of these procedures is discussed in detail below: 1.
Operation (cont’d) Adjusting / repairing. Before working on the generator or engine, always turn off engine and remove spark plug(s) or spark plug wire(s) to prevent accidental starting. Always discharge the capacitor before working on the generator head to prevent electrical shock. (See Maintenance & Repair section of this manual for instructions on how to do this.) Carbon monoxide poisoning. The running engine gives off carbon monoxide, a poisonous gas that can kill you.
Operation (cont’d) 2. Preparing for Operation (Pre-start checklist) Mount generator & engine Check that the generator and engine are mounted and connected in accordance with the instructions given earlier in this manual in the “Installation / Initial Set-up” section, “Step 5: Mount & Connect Generator and Engine”.
Operation (cont’d) Check/fill fuel tank Check the engine fuel level. If needed, fill tank with fresh fuel from a portable container after first reading the following instructions and warnings: 1) Allow engine to cool for at least two minutes before removing gas cap. Note: A running or still-hot engine is hot enough to ignite fuel. 2) When adding fuel: - Use only a UL-approved portable fuel container to transfer fuel. Follow the safety warning and instructions below for avoiding static electric sparking.
Operation (cont’d) Personal Protection Always dissipate static charge from your body before beginning the fueling process by touching a grounded metal object at a safe distance from fuel sources. Never fill the generator’s fuel tank directly from the pump – the generator’s tank is not grounded and high velocity flow from the pump can cause static electricity build-up. Use an approved portable container to transfer gas to the generator’s tank.
Operation (cont’d) 3. Starting the Generator After you have completed the pre-start checklist procedures, you are ready to start the generator. Start engine Start the engine with the guard in place. Check output voltage without load Before starting, confirm there are no loads connected to the generator’s outlets. Follow the instructions provided in your engine manual for starting the engine. Check output voltage before connecting loads to the generator.
Operation (cont’d) 4. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. Instructions are provided below for connecting loads when you are using the generator: o As a portable power source o Connected to a building as a back-up power source WARNING: Do not overload generator.
Operation (cont’d) If output voltage is not within the acceptable range, adjust the engine speed (if possible). If acceptable output voltage cannot be achieved no matter what the engine speed, the generator is either overloaded or there is a problem with either the engine or the generator. Shut off the engine and refer to the Troubleshooting guide at the end of this manual for assistance with possible problems. Note: Expect slight variations in voltage/speed with changing electrical loads.
Operation (cont’d) 5. Stopping Stop the generator using the following steps: 1. Disconnect all loads to generator. (Never turn off or reduce engine speed with electrical loads connected. Damage to generator and loads will occur.) 2. Shut OFF the engine 3. Shut OFF fuel supply to the engine if possible. 4. Remove spark plug to prevent accidental starting of engine. 6.
Operation (cont’d) Exercise generator every 4 weeks The generator should be exercised regularly. At least every four weeks, start the engine and let it run for 10 to 15 minutes with a small load plugged in, such as a lamp or fan. Monthly exercising of the generator will: o Dry out any moisture that has accumulated in the windings. If left, this moisture can cause corrosion in the winding. o Ensure that the unit is operating properly should it be needed in an emergency.
Maintenance & Repair Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance steps. WARNING ALWAYS shut off the engine, disconnect the engine’s spark plug(s), and discharge the capacitor before cleaning, adjusting, or servicing the generator. Make sure all guards and shields are replaced before using. Note: The generator head is brushless and maintenance free.
Maintenance & Repair (cont’d) belts and couplings 1. Make sure that the mounting bolts are tight and secure. 2. Check belt (if applicable) and pulleys for looseness or signs of wear. Adjust or replace as necessary. 3. Check coupling (if applicable) for signs of wear or misalignment. Replace/realign as needed. Perform engine maintenance Perform engine maintenance as specified in the engine owner’s manual. Engine maintenance items may include: 1. 2. 3. 4. 5. 6. 7. 8.
Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Voltage too low. a. Engine speed too slow. a. Bring generator to a qualified technician for adjustment. b. Reduce the load. (See Power Load Planning & Mgt section of this manual.) c. Tighten belt. (Or tighten coupler) a. Disconnect load. b. Generator is overloaded. Circuit breaker trips. c. Belt slippage. (Or coupler slippage) a. Defective load connected to generator. b. Defective receptacle. c. Generator overloaded.
Summary of Important Safety Information This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your generator. WARNING Carefully read and make sure you understand the following safety information before using the generator.
Summary of Important Safety Information (cont’d) barns, sheds, or other semi-enclosed spaces. These spaces can trap poisonous gases, EVEN if you run a fan or open windows. Cooling ventilation. The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head so it does not overheat and possibly cause fire. Situate so there is adequate clearance around generator to allow for cooling airflow. Do not allow debris to accumulate and block airflow.
Summary of Important Safety Information (cont’d) Sparks/Smoking. Never smoke or work near sparks or other sources of ignition. Electric shock. Never touch both battery terminals at the same time with your hand or any non-insulated tools. Connection/disconnection sequence. ALWAYS connect and disconnect cables to the correct battery terminals in the proper sequence: o When CONNECTING the battery, connect the RED cable to the POSITIVE terminal FIRST.
Summary of Important Safety Information (cont’d) Electric shock accident. If an electric shock accident occurs, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. Avoid direct contact with victim. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. Apply first aid and get immediate medical help. Hot parts.
Generator Exploded View – Rev F.
Wiring Diagram – Rev F.
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Limited Warranty Dear Valued Customer: The NorthStar Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a NorthStar product, you show a desire for quality and durability. Like all mechanical equipment this unit requires a due amount of care. Treat this unit like the high quality piece of machinery it is. Neglect and improper handling may impair its performance.
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