MODEL 10000 BDG
ITEM # 165928
Belt Driven Generator
P r o v e n P e r f o r m a n c e
M165928A
OWNER’S MANUAL
00287
10000 BDG
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 Central Standard Time
SPECIFICATIONS
Item Number
Maximum Output
Continuous Output
Voltage
Phase
Frequency
Power Factor
Minimum Recommended
Engine
#165928
10000 Watts (W)
9600 Watts (W)
120 / 240 Volt (V)
Single phase (4-wire)
58.0-63.0 Hertz (Hz)
1.0 p.f.
18 Hp
Engine Speed
120VReceptacle
3480-3780 RPM
(2) 20 Amp (A) duplex (NEMA 5-20R)
30 Amp (A) twistlock (NEMA L5-30R)
50 Amp (A) Straight blade (NEMA14-50R)
(2) 20 Amp (A) thermal, push to resetstyle
30 Amp (A) thermal, push to resetstyle
(2) 40 Amp (A) thermal, push to resetstyle
28 mm diameter X 2.38”
120/240VReceptacle
Circuit Breaker
Drive Shaft
8 mm X 1.75” key way
Dimensions
Length
Width
Height
Gross Weight
19.50” (49.5 cm)
14.25” (36.2 cm)
9.00” (22.9 cm)
110 lb. (50 kg)
2
MACHINE COMPONENT IDENTIFICATION
00289
ꢀ
Figure 1 (Ref. 1-7)
Ref. Description
Ref. Description
1
2
3
4
5
6
40A Circuit Breakers
30A Circuit Breaker
7
8
120/240V 50A Receptacle
28 mm shaft
20A Circuit Breakers
Voltmeter
120V 20A Duplex Receptacles
120V 30A Twistlock Receptacle
9
Grounding screw
10
11
Mounting feet
Fan vents
ꢃ
00290
ꢂꢂ
ꢁ
Figure 2 (Ref. 8-11)
3
NorthStar is constantly improving its products.
The specifications outlined herein are subject to
GENERATOR FEATURES
change without prior notice or obligation.
The
References 1-3 Circuit Breakers.
• Reference 1 - two 40 amp (A) push-to-reset
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.
circuit breakers.
Reference 2 - one 30 amp (A) push-to-reset
circuit breaker.
•
•
Reference 3 - two 20 amp (A) push-to-reset
circuit breakers.
Reference 4 - Voltmeter.
Voltmeter needle
ANSI SAFETY DEFINITIONS
should be in green area during all generator load
conditions. The black line in the center on the green
area is 120V. During no load conditions, the needle
should be at or above the black line.
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.
References 5-6 120V Receptacles.
•
Reference 5 - The generator has a side panel
with two 120 volt (V) 20 amp (A) straight blade
receptacle duplexes (two receptacles in a common
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in a
death or seri ous i nj ury.
housing).
Association (NEMA) number is 5-20R.
Reference 6 - This twistlock is a 120V 30A
National
Electrical
Manufacturer’s
•
receptacle, NEMA number L5-30R. This receptacle
accepts NEMA plug number L5-30P, which is supplied
with the generator.
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.
Reference 7 - 120/240V Receptacle.
This
straight blade receptacle is 120/240V 50A, but has two
40A ci rcui t breakers to l imi t m axim um current. T hi s
receptacle accepts a NEMA plug number 14-50P,
which is supplied with the generator.
RULES FOR SAFE OPERATIONS
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 8 - 28 mm diameter Shaft. The shaft
is 2.375” long and has a 8 mm key way. A taper bore
or split bore bushing is recommended for attaching
sheaves. 8 mm X 1.75” key supplied with generator.
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:
Reference 9 - Ground Screw.
Ground the
generator via the ground screw, to a copper pipe or
rod that is driven into moist soil.
WARNING This generator is equipped
with a grounding screw, located on the generator
Reference 10 - Mounting feet. Use these three
locations to attach the generator head in place with
7/16” grade 5 bolts. Mounting plates (item #165935)
for mounting generator to a cement pad are available
through Northern and the NorthStar parts catalog.
Reference 11 - Fan Vents. Never block the vent
slots or insert objects through the slots. The closest
object should be a minimum of 3 feet away from the
vents.
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.
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.
4
ALWAYS remove the spark plug or spark plug
wire before working on the engine or generator, this
prevents accidental starting.
The generator shaft is 28 mm diameter X 2.38” long
with a 8mm key way. The table below shows the
recommended horsepower and sheaves .
The shaft speed of the generator must be between
3480-3780 RPM. At no load the correct speed is 3780
RPM. If the engine is a 3750 RPM engine, then a
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
Double Sheave Dia. Double Sheave Dia.
Engine Hp
V-Belt Type
Quantity
V-Belt Type
Quantity
cause damage to generator and possible injury to
00039
people.
6.60”
B Belt
2
6.00”
3VX Belt
2
ALWAYS remove all oil or gasoline deposits and
accumulated dirt from generator and immediate area.
Keep generator head and engine clean.
18 Hp
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.
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.
L. Without proper guarding in place.
WARNING Keep fire extinguisher close
by your generator and be familiar with how to use it.
Consult your local fire department for correct
extinguisher type.
INSTALLATION
Figure 3
NOTE: Guards are removed to show details
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
00291
DANGER Always have proper guar
of the V-belt(s) and sheaves to prevent access to any
pinch points. Failure to guard the power transmission
mechanisms may result in serious injury or death.
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 of 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 the 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.
Foot print of
mounting feet
is shown at left.
The user shall determine the pr
Use 7/16”
tensioning method for their specific use.
grade 5 bolts.
To determine belt tension:
Measure L - the center to center distance of the two
00292
sheaves.
Measure d - the deflection of the belt.
Optional mount kit (item #165935) is available in
the Northern catalog and the NorthStar parts
5
00307
catalog. Includes 2 plates and mounting hardware.
Tighten or loosen belt until:
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
d = 0.016 X L
If the control box is not located on the correct
side for your application, it can be rotated to the
opposite side. First remove the fan vents, than
remove the four drive end bracket bolts. Rotate the
drive end bracket 180°, re-torque bolts to 17 ft•lb.
Reinstall the fan vents. Remove the four screws at the
base of control box, rotate the control box 180°. The
voltmeter is now on the back of the machine instead of
the front. See below for terminology.
multiplying
amperage.
nameplate voltage by nameplate
VOLTS X AMPS = WATTS
Example: 120V X 5A
= 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
DANGER Remember, exhaust fumes are
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
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.
deadly carbon monoxide gas, and must be vented to
the outside where there are no people. Cooling air of
sufficient amounts must be brought in and exhausted
out to ensure proper cooling of the engine and
generator.
If you desire to direct couple the generan
00298
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 hazards or
death.
Starting Amps
RI type Cap type SP type
120V, 60 Hz Motors
Hp motor Running
Watts
LOAD APPLICATION
1/6
1/4
1/3
1/2
1
1 1/2
2
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
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
11-18
15-25
24-40
30-50
36-60
51-85
84-140
3
5
6
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.
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.
Compressor (1/2 HP)
Curling Iron
Dishwasher
1400 (a)
700
1200
Edge Trimmer
500
Electric Nail Gun
Electric Range (one element)
Electric Skillet
Freezer
Furnace Fan (1/3 HP)
1200
1500
1250
800 (b)
1200 (a)
1200
1100
875
500
250
450
150
Hair Dryer
Hand Drill (1”)
Hand Drill (1/2”)
Hand Drill (3/8”)
Hand Drill (1/4”)
Hedge Trimmer
Home Computer
Impact Wrench
Jet Pump
Lawn Mower
Light Bulb
Microwave Oven
500
800 (a)
1200
100
700
1100 (a)
300
400
225
150
4500
600 (a)
150
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 (handheld)
Radio
EXTENSION CORDS
200
Refrigerator
Slow Cooker
Submersible Pump (1-1/2 HP)
Submersible Pump (1 HP)
Submersible Pump (1/2 HP)
Sump Pump
Table Saw (10”)
Television
Toaster
Vacuum cleaner
VCR
600 (b)
200
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.
2800 (a)
2000 (a)
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’
*
Water Heater
Weed Trimmer
(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.
NOTE: For extremely hard to start loads such as
air conditioners and air compressors, consult the
equipment dealer to determine the maximum wattage.
*
CAUTION: Equipment damage can result from the
low voltage caused by using an extension cord with a
sm all wi re si ze.
Use this chart to estimate the total load on your
generator.
For Determining Generator Load Requirements
PRE-START UP PREPARATIONS
Device
Running Watts
1700 (a)
500
Air Conditioner (12,000 Btu)
Battery Charger (20 Amp)
Belt Sander (3”)
Your generator has been thoroughly tested prior to
shipment from the factory. 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.
1000
Chain Saw
1200
Circular Saw (6-1/2”)
Coffee Maker
900
1000
Compressor (1 HP)
Compressor (3/4 HP)
2000 (a)
1800 (a)
*Not recommended
7
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 10 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.
this moisture can cause corrosion in the winding.
Frequent operation of the 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 NorthStar APPROVED
REPAIR PARTS AVAILABLE AT 1-800-270-0810.
A. Bearing - The bearings used in this generator
are a heavy duty, sealed ball bearing type. They
require no maintenance or lubrication.
OPERATING SPEED
The generator must be run at the correct speed in
order to produce the proper electrical voltage and
frequency.
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.
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 effected if correct RPM is
not maintained. See Load vs. Output chart
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.
Load
Output
Frequency
Percent of
Generator
Output
Speed
(RPM)
Generator
voltage at 120V
Receptacle
(Hz)
0 %
50 %
100 %
3780
3600
3480
63.0
60.0
58.0
125V
122V
118V
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.. 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,
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.)
c) Tighten belt(s). (or tighten coupler)
a) Disconnect load.
c) Belt slippage. (or coupler slippage)
a) Defective load connected to generator.
b) Defective receptacle.
Circuit breaker trips.
Voltage too high.
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.
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) Replace receptacle.
d) Bring generator to a qualified
technician for repair.
c) Defective receptacle.
d) Defective stator.
e) Defective rotor.
e) Bring generator to a qualified
technician for repair.
f) Defective capacitor.
g) Defective circuit breaker.
f) Bring generator to a qualified
technician for repair.
g) Bring generator to a qualified
technician for repair.
h) Belt(s) is slipping or broken. (or coupler
slipping or broken)
h) Tighten or replace belt(s). (tighten or
replace coupler)
9
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