North Star Portable Generator 5500 BDG User Manual

MODEL 5500 BDG, ITEM #165913  
Belt Driven Generator  
M165913B  
P r o v e n P e r f o r m a n c e  
OWNER’S MANUAL  
Any Questions, Comments, or Problems?  
Call Customer Service at 1-800-270-0810  
 
SPECIFICATIONS  
Item Number  
Maximum Output  
Continuous Output  
Voltage  
#165913  
5500 Watts (W)  
5000 Watts (W)  
120 / 240 Volt (V)  
Phase  
Frequency  
Power Factor  
Engine  
Engine Speed  
120 VReceptacle  
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)  
240 VReceptacle  
20 Amp (A) Locking Device  
(NEMAL6-20R)  
Circuit Breaker  
Dimensions  
Length  
Width  
Height  
20 Amp (A) thermal, push to reset style  
16.25” (413 cm)  
7.25” (184 cm)  
7.75” (197 cm)  
53 lb. (24.1 kg)  
Gross Weight  
.
2
 
MACHINE COMPONENT IDENTIFICATION  
Figure 1 (Ref. 1-4)  
00041  
Ref. Description  
Ref. Description  
1
2
3
4
Circuit Breakers  
5
6
7
7/8” shaft  
120V 20A Duplex Receptacle  
240V 20A Locking Receptacle  
Grounding screw  
Mounting feet  
Fan vents  
Figure 2 (Ref. 5-7)  
00042  
3
 
WARNING indicates a potentially hazardous  
situation which, if not avoided, could result in a  
death or seri ous i nj ury.  
GENERATOR FEATURES  
Reference 1 - Circuit Breakers. This belt driven  
single phase generator has 2, 20 amp (A) push to  
reset circuit breakers to protect against electrical  
overloads.  
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.  
Receptacles  
Reference 2 - 120V Receptacle. The generator  
has an end cover with one duplex (two receptacles in  
a common housing) receptacle and one locking device  
receptacle. The duplex is a 120 volt (V) 20 amp (A)  
RULES FOR SAFE OPERATIONS  
straight blade  
receptacle,  
National  
Electrical  
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:  
Manufacturer’s 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  
device is a 240V 20A NEMA L6-20R 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.  
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.  
WARNING This generator is equipped  
with a grounding screw, located on the generator  
Ground the  
frame 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.  
Reference 6 - Mounting feet. Use these three  
locations to bolt the generator head in place.  
Reference 7 - Fan Vents. Never block the vent  
sl ots or i nsert objects through the sl ots.  
ALWAYS use electrical cords that are in good  
condition. Worn, bare, frayed or otherwise damaged  
cords can cause electric shock.  
INTRODUCTION  
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.  
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 performance and long life of the  
generator.  
ALWAYS use a ground fault circuit interrupter  
(GFCI) in damp or highly electrical conductive areas  
and on construction job-sites to prevent electric shock.  
North Star is constantly improving its products.  
The specifications outlined herein are subject to  
ALWAYS remove the spark plug or spark plug  
wire before working on the engine or generator, this  
prevents accidental starting.  
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.  
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 will  
cause damage to generator and possible injury to  
people.  
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.  
4
 
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.  
B. Overheating in load connecting devices.  
C. Sparking or arcs from generator.  
D. Loss of electrical output.  
E. Damaged receptacles.  
F. Engine misfire.  
G. Excessive vibration.  
H. Enclosed compartments, or confined  
areas.  
I. Flame or smoke.  
J. Rain, snow or wet conditions.  
K. Operator non-attendance.  
WARNING Keep fire extinguisher  
The shaft speed of the generator must be between  
3540-3720 RPM. At no 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 constant  
vibration and stresses that will be produced. See figure  
3 for a possible mounting configuration.  
The user shall determine the proper belt  
tensioning method for their specific use.  
close by 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 not tip 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.  
To determine belt tension:  
Measure L - the center  
to center distance of the  
two sheaves  
Measure d - the  
deflection of the belt.  
Tighten or loosen belt  
until:  
d = 0.016 X L  
00039  
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.  
Single Sheave Dia. Double Sheave Dia.  
Engine hp  
Belt Type - Qty.  
Belt Type - Qty.  
5.00”  
Notched V-Belt - 1  
5.80”  
4.60”  
V-Belt - 2  
5.00”  
NEVER install your generator inside confined  
areas. Inside installation can cause health hazards or  
death.  
9 hp  
11 hp  
Notched V-Belt - 1  
V-Belt - 2  
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.  
Figure 3  
00038  
Note: Guards are removed to show details.  
5
 
Cooling air of sufficient amounts must be brought in  
and exhausted out to ensure proper cooling of the  
engine and generator.  
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.  
DANGER Remember, exhaust fumes are  
deadly carbon monoxide gas, and must be vented to  
the outside where there are no people.  
Starting Amps  
RI type Cap type SP type  
120V, 60 Hz Motors  
Hp motor Running  
Watts  
1/6  
1/4  
1/3  
1/2  
1
1 1/2  
2
3
525  
700  
875  
1175  
1925  
2400  
2900  
4075  
6750  
7-11  
9-15  
9-18  
12-23  
14-29  
20-40  
32-64  
40-80  
48-96  
68-136  
112-224  
16-22  
22-32  
26-35  
NA  
NA  
NA  
NA  
NA  
NA  
LOAD APPLICATION  
11-18  
15-25  
24-40  
30-50  
36-60  
51-85  
84-140  
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 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 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  
5
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 it is  
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 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 will burn out in a  
short time. The generator head winding might also be  
damaged.  
multiplying  
amperage.  
nameplate voltage by nameplate  
VOLTS X AMPS = WATTS  
Example: 120V X 5A  
= 600W  
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 off all other electrical  
loads and if possible reduce the load on the electric  
motor.  
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.  
EXTENSION CORDS  
STARTING ELECTRIC MOTORS  
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 a minimum.  
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. 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  
6
 
Submersible Pump (1/2 HP)  
Sump Pump  
Table Saw (10”)  
Television  
Toaster  
Vacuum cleaner  
VCR  
Water Heater  
Weed Trimmer  
1500 (a)  
600 (a)  
2000 (a)  
500  
1000  
250  
70  
3000  
500  
Current/Power Maximum Extension Cord Length  
Amps  
at  
Load  
(watts)  
#10  
Ga.  
#12  
Ga.  
#14  
Ga.  
#16  
Ga.  
240V  
Cord  
Cord  
Cord  
Cord  
10  
20  
30  
40  
50  
2400  
4800  
7200  
9600  
12000  
250’  
125’  
60’  
30’  
15’  
150’  
75’  
35’  
15’  
*
100’  
50’  
25’  
10’  
*
75’  
25’  
10’  
*
*
(a) Hard-starting motors require 3 to 5 times the  
rated running watts.  
(b) These loads may require up to 15 minutes to  
restart due to its normal build up of compressor head  
pressure.  
*Not recommended  
CAUTION: Equipment damage can result from the  
low voltage caused by using an extension cord with a  
sm all wi re si ze.  
NOTE: For extremely hard to start loads such as  
air conditioners and air compressors, consult the  
equipment dealer to determine the maximum wattage.  
Use this chart to estimate the total load on your  
generator.  
For Determining Generator Load Requirements  
Device  
Running Watts  
1700 (a)  
500  
PRE-START PREPARATIONS  
Air Conditioner (12,000 Btu)  
Battery Charger (20 Amp)  
Belt Sander (3”)  
Chain Saw  
Circular Saw (6-1/2”)  
1000  
1200  
900  
1000  
2000 (a)  
1800 (a)  
1400 (a)  
700  
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, loose or missing nuts and bolts. If the  
aforementioned problems occur, call customer service  
at 1-800-270-0810.  
Coffee Maker  
Compressor (1 HP)  
Compressor (3/4 HP)  
Compressor (1/2 HP)  
Curling Iron  
Dishwasher  
Edge Trimmer  
Electric Nail Gun  
Electric Range (one element)  
Electric Skillet  
Furnace Fan (1/3 HP)  
Freezer  
1200  
500  
1200  
1500  
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 a 12 gauge wire from the clamp to the generator  
ground screw. Do not connect to a water pipe or a  
ground used by a radio system.  
1250  
1200 (a)  
800 (b)  
1200  
Hair Dryer  
Hand Drill (1”)  
Hand Drill (1/2”)  
1100  
875  
OPERATING SPEED  
Hand Drill (3/8”)  
Hand Drill (1/4”)  
Hedge Trimmer  
Home Computer  
Impact Wrench  
Jet Pump  
Lawn Mower  
Light Bulb  
Microwave Oven  
500  
250  
450  
150  
500  
800 (a)  
1200  
100  
700  
1100 (a)  
300  
400  
225  
150  
4500  
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 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.  
Milk Cooler  
Oil Burner on Furnace  
Oil Fired Space Htr (140,000 Btu)  
Oil Fired Space Htr (85,000 Btu)  
Oil Fired Space Htr (30,000 Btu)  
Oven  
Paint Sprayer, Airless (1/3 HP)  
Paint Sprayer, Airless (hand held)  
600 (a)  
150  
Load Requirements Continued  
Radio  
Refrigerator  
200  
600 (b)  
200  
Slow Cooker  
Submersible Pump (1-1/2 HP)  
Submersible Pump (1 HP)  
2800 (a)  
2000 (a)  
7
 
Load  
Output  
Frequency  
Percent of  
Generator  
Output  
Speed  
(RPM)  
Generator  
voltage at 120V  
Receptacle  
WARNING, Stand-by Operation  
(Hz)  
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.  
0 %  
50 %  
100 %  
3720  
3600  
3540  
62.0  
60.0  
59.0  
129V  
120V  
115V  
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 wrist watch or a stop watch the  
clock should be correct within +/- 2 seconds per  
minute. All speed 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. Warm 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 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 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 receptacles can be both dangerous to the  
operator and destructive to the equipment.  
8
 
TROUBLESHOOTING  
Problem  
Possible Causes  
Possible Remedies  
Voltage too low.  
a) Engine speed too slow.  
a) Bring generator to a qualified  
technician for adjustment.  
b) Generator is overloaded.  
b) Reduce the load. (See Load  
Application section of this manual.)  
a) Disconnect load.  
Circuit breaker trips.  
a) Defective load connected to generator.  
b) Defective receptacle.  
b) Replace receptacle.  
c) Generator overloaded.  
c) Reduce the load. (See Load  
Application section of this manual.)  
a) Bring generator to a qualified  
technician for adjustment.  
Voltage too high.  
a) Engine speed too high.  
Generator overheating. a) Generator is overloaded.  
b) Insufficient ventilation.  
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) Disconnect load.  
No output voltage.  
a) Defective load connected to generator.  
b) Broken or loose wire.  
b) Bring generator to a qualified  
technician for repair.  
c) Defective receptacle.  
d) Defective stator.  
c) Replace receptacle.  
d) Bring generator to a qualified  
technician for repair.  
e) Bring generator to a qualified  
technician for repair.  
e) Defective rotor.  
f) Defective capacitor.  
a) Generator is overloaded.  
b) Dirty air filter.  
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.  
Engine lacks power.  
9
 

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