North Star 8000 IPG User Manual

M165920S

ITEM NUMBER: 165920

Owner’s Manual

Instructions for Installation/Set-up, Operation, Servicing, & Storage

Portable, Outdoor Use-Only, Industrial Gasoline Generator

SERIAL NUMBER: _____________

6,600 Watt Continuous (8,000 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.

WARNING

READ and UNDERSTAND this manual completely before using the generator! Failure to properly set up,

operate, and maintain this generator could result in serious injury or death from carbon monoxide poisoning, electric shock, fire/explosion, or burns. In particular, be aware of the following hazards:

Generators give off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it.

• ONLY run generator OUTDOORS and AWAY from building air intakes. NEVER run generator inside any enclosed or semi-enclosed spaces, including homes, basements, garages, sheds , boxes , RVs, boats or pick-up truck beds. These spaces can trap poisonous gases, EVEN if you run a fan or open windows.

• Install carbon monoxide alarms inside nearby structures/buildin gs (bat t er y -o perat ed , or plug-in with battery backup).

Electric shock / Electrocution

• High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly grounded. Use only UL-listed, outdoor-rated grounded extension cords of proper size.

• NEVER plug the generator directly into a wall outlet. ANY connection to a building’s electrical system MUST ISOLATE THE GENERATOR FROM UTILITY POWER via a UL-approved transfer switch installed by a licensed electrician. Otherwise, back feed from the generator into the power grid could kill utility workers.

• DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so engine does not overheat. Exhaust can be extremely hot. Keep muffler at least 7’ from all combustible objects.

• All fuels are flammable. Never fuel a running or hot engine. Never pump fuel directly into generator at gas station – use approved container to transfer fuel. Ensure there are no fuel leaks, and keep sources of sparks and flames away.

• ALWAYS keep a fire extinguisher rated “ABC” nearby.

CO Poisoning

Fire / Explosion

STOP!

CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the “Power load Planning & Management” section

of this manual to determine your power load requirements and then compare to the generator’s rated capacity.

INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the “Unpacking

& Delivery Inspection” section for instructions on whom to contact to report missing or damaged parts.

ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator

to your building’s electrical system. See the “Installation/Initial Set-Up” section for more information about this

requirement.

Any Questions, Comments, Problems, or Parts Orders

Call NorthStar Product Support 1-800-270-0810

Hazard Signal Word Definitions

Table of Contents

Hazard Signal Word Definitions .................................................................................................2

About Your Generator .................................................................................................................4

Specifications .................................................................................................................................6

Safety Label Locations..................................................................................................................7

Machine Component Identification.............................................................................................8

Power Load Planning & Management........................................................................................10

Installation / Initial Set-Up:

1. Unpacking & Delivery Inspection..........................................................................................12

2. Planning the Power Load........................................................................................................12

3. Set-up as a PORTABLE or BUILDING BACK-UP Power Source ......................................13

4. Selecting a Suitable Site.........................................................................................................16

5. Grounding the Generator........................................................................................................18

6. Battery Installation .................................................................................................................19

Operation:

1. General Safety Rules for Operation .......................................................................................20

2. Preparing for Operation..........................................................................................................23

3. Starting the Engine.................................................................................................................26

4. Checking Generator Output....................................................................................................27

5. Connecting Loads...................................................................................................................28

6. Stopping the Engine ...............................................................................................................28

7. Storage & Exercise.................................................................................................................29

Maintenance & Repair..................................................................................................................31

Troubleshooting.............................................................................................................................33

Summary of Important Safety Information for Operation.......................................................34

Generator Exploded View............................................................................................................38

Wiring Diagram.............................................................................................................................40

Generator Head Exploded View..................................................................................................42

Limited Warranty.........................................................................................................................43

About Your Generator

Thank you for purchasing your NorthStar portable generator!

This engine-driven, portable generator is designed to provide up to 8000 Watts of electrical power (6600 watts continuous, 8000 watts surge). It 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. A licensed electrician can connect

the generator to your building’s electrical system via the installation of an UL-approved transfer switch. (See the “Installation & Initial Set-up” section of this manual to learn more about specific requirements and precautions relating to wiring the generator to your building’s electrical system.)

You must select a generator adequately sized for your power needs. You need to determine the power needs of all the appliances/tools you wish to power at the same time and choose a generator rated to provide at least that power level. See the “Power Load Planning & Management” section of this manual to determine your specific power load requirements and then compare them to this generator’s rated capacity. You must not overload the generator. Overloading will cause damage to the generator and attached electrical devices, and may also result in fire

Be sure to read about site selection and grounding requirements for running this generator. More detailed information can be found in the “Installation & Initial Set-up, Steps

5 & 6” of this manual. This generator is too heavy for one person to lift without mechanical assistance. An

optional wheel kit is available from NorthStar and is recommended if you will be moving the generator unassisted. Other optional accessories available from NorthStar include a vi nyl cover for storage, UL-approved transfer switches, and extension cords.

Contact NorthStar Product Support at 1-800-270-0810 with questions about optional accessories or to order.

Read this Manual

About Your Generator

Improper use or maintenance of this generator can result in serious injury or death from

carbon monoxide poisoning, electric shock/electrocution, fire/explosion, or burns.

Read this manual completely before using the generator and follow all instructions and

safety rules.

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. For detailed engine operation and maintenance information, always refer to the engine Owner’s Manual furnished with the generator.

WARNING

About Your Generator (cont’d)

NorthStar is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation. The purchaser and/or user shall assume liability for any modification and/or alterations of 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.

Contact NorthStar Product Support at 1-800-270-0810 for any questions about the

appropriate use of this generator.

Warranty Registration

Please fill out and submit the warranty registration card so that we have your contact information for any future product literature or replacement parts you may need.

ATTENTION:

All Rental Companies and Private Owners who loan this

All persons to whom you rent/loan this generator must have access to and read this manual. Keep this owner’s manual with the generator at all times and advise all persons who will operate the machine to read it. You must also provide personal instruction on how to safely operate the generator and remain available to answer any questions a renter/borrower might have.

equipment to others!

Specifications

SPECIFICATIONS

Item Number 165920 Maximum Output 8000 Watts (W) Continuous Output 6600 Watts (W) Voltage 120 / 240 Volt (V) Phase Single phase (4-wire) Frequency 56.5 - 63.3 Hertz (Hz) Power Factor 1.0 p.f. Engine 13 HP Honda GX390 Engine Speed 3390 - 3798 RPM Fuel Type Unleaded gasoline Fuel Capacity 6.5 gallons (24.6 L) Oil Capacity 1.16 US quarts (1.1 L) Starting Method Electric Start / Recoil 120 V Receptacle (2) 20 Amp (A) duplex GFCI (NEMA 5-20R)

(1) 30 Amp (A) locking device (2) (NEMA L5-30R)

(1) 50 Amp (A) straight blade (NEMA 5-50R) 120/240 V Receptacle 30 Amp (A) locking device (NEMA L14-30R) Circuit Breaker (2) 20 Amp (A) Thermal, push to reset

(1) 30 Amp (A) Thermal, push to reset (1) 50 Amp (A) Thermal, push to reset

(1) 30 Amp (A) Magnetic, 2 Pole Grounding Post Receives 10 Ga. wire or fork terminal Battery (not included)

Dimensions

Length 31.75” (80.6 cm) Width 23.63” (60.0 cm) Height 22.25” (56.5 cm) Dry Weight 225 lb (103 kg) Gross Weight 280 lb (128 kg)

12 Volt, Group size U1

170 CCA, 18 amp-hr

Safety Label Locations

WARNING

BURN HAZARD

Do not touch hot muffler.

PN 39260

• Commercial-grade electric start engine

• Extend run 6.5 gallon fuel tank

• Maintenance-free brushless alternator design

• Smooth running focus mount isolation system

BATTERIES:

1) contain caustic acid, 2) emit explosive gases, 3) can cause electric shock

ALWAYS use eye protection. Caustic acid and explosive gases can cause blindness or severe burns. NO smoking, sparks, or flames. NEVER touch both battery terminals at the same time with your hand or any non-insulated tools. FLUSH immediately with water if battery acid contacts eyes, skin, or clothing.

CONNECT cables in correct sequence: FIRST RED to POSITIVE terminal, then BLACK to NEGATIVE

terminal. When disconnecting, DISCONNECT BLACK cable first, then RED. NEVER charge a visibly damaged or frozen battery. ALWAYS read and follow charger instructions.

IF GENERATOR IS TO BE STORED LONGER THAN 2 MONTHS,

charge battery with a trickle charger that is rated for 3 amps maximum.

WARNING - BATTERY HAZARDS

ATTENTION

A charged battery ensures reliable engine starting.

PN 779396

• Commercial-grade electric start engine

• Extend run 6.5 gallon fuel tank

• Maintenance-free brushless alternator design

• Smooth running focus mount isolation system

Always make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result.

To order replacement safety labels, call NorthStar Product Support at 1-800-270-0810.

On-Product Warning Labels

Part numbers Description

39260 Burn Warning 779422 NorthStar 779423 Warning

779396 Battery Warning

Machine Component Identification - Item #165920S

Figure 1 (Ref. 1-13)

Ref.

Description Ref. Description

1 Air Cleaner 11 Gas Cap with Gauge 2 Oil Drain Plug 12 6.5 Gallon Gas Tank 3 Full Power Switch 13 Super Silent Muffler 4 Voltmeter 14 Generator Head 5 Idle Control On/Off Switch 15 Battery Box 6 Hour Meter 16 Vibration Isolation Mount 7 Main Line Circuit Breaker 30A 17 Recoil 8 50A Circuit Breaker 18 Fuel Shut-Off Valve 9 30A Circuit Breaker 19 Choke Lever

10 20A Circuit Breaker 20 Engine Starting Key

Figure 2 (Ref. 14-20)

Machine Component Identification - Item #165920S

REFERENCE GUIDE

Reference 1 – Air Cleaner Reference 2 – Oil Drain Plug

Reference 3 – Full Power Switch

Reference 4 – Voltmeter Reference 5 – Idle Control On/Off

Switch

Reference 6 – Hour Meter Reference 7 – Main Line Circuit Breaker 30A Reference 8 – 50A Circuit Breaker Reference 9 – 30A Circuit Breaker Reference 10 – 20A Circuit Breaker Reference 11 – Gas Cap with Gauge

Reference 12 – 6.5 Gallon Gas Tank

Reference 13 – Super Silent Muffler Reference 14 – Generator Head Reference 15 – Battery Box

Reference 16 – Vibration Isolation Mount

Reference 17 – Recoil Reference 18 – Fuel Shut-Off Valve

Reference 19 – Choke Lever Reference 20 – Engine Starting Key

Refer to your Honda engine manual for air cleaner care. Refer to your Honda engine manual for oil change recommendations. The switch reconnects the two generator windings from parallel (120V only) to series (120/240V).

• 120V Only

any combination of 120 volt receptacles. The 120/240V 30A locking device receptacle is 120V only at this time.

• 120/240V

However, only half the power or 3300 watts (27.5A), can be used at any one 120V receptacle. 120V output can

total 6600 watts. Voltmeter needle should be in green area during all generator load conditions.

This feature senses the load on the generator. With no load on the generator the engine speed drops to idle. This saves fuel and lengthens engine life. When a load is applied, the engine speed returns to 3600 - 3780 RPMs. Turning the switch off disables the sensing device and the generator will run at 3600 - 3750 RPM whether or not a load is applied.

Note: When the engine is idling, it is normal for the

voltmeter needle to be in the red range.

Allows for better maintenance scheduling of generator. 30 amp (A) magnetic 2-pole main circuit breaker to protect against electrical overloads. 50 amp (A) push-to-reset circuit breaker 30 amp (A) push-to-reset circuit breaker 20 amp (A) push-to-reset circuit breaker The gas cap is extra large, creating a large hole for refueling. You can monitor the fuel level without removing the cap by using the fuel level indicator built into the gas cap. Large tank allows for extended run capabilities. ALWAYS allow room for gasoline expansion by not filling the gas tank completely full. 4 dB less than Honda’s standard muffler. The electricity producing part of the generator. The battery box provides protection for the battery and will accept a standard lawn tractor size battery (Group U1-7). The engine requires a 12-volts battery, with a minimum rating of 18Ah (Amp-Hour). See battery section for sizing. The engine and generator 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. Grasp firmly when starting engine. Consult engine manual for further instruction. The engine is equipped with an ON-OFF valve located on the left side of the recoil. ALWAYS keep this valve closed when the generator is not in use. Used during cold starts. Refer to the starting/stopping instructions and the Honda engine manual for usage. The engine key is located on the engine. Always locate this switch and be familiar with its location before operating the generator.

: Allows all 6600 watts (55A) to be used in

: Allows all 6600 watts to be used for 240V.

Power Load Planning & Management

WARNING

NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and

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. The sum of the running and starting wattages of the devices being powered must not exceed the continuous output rating of your generator. (The continuous output rating of your generator is listed in the “Specifications” section of this manual.) Note that:

• Devices without electric motors such as light bulbs, radios, and televisions have the same

• Devices with electric motors such as refrigerators, compressors, and hand tools typically

The running and starting wattage requirements are often listed on a device’s nameplate. If wattage is not given on the device’s nameplate, the wattage may be calculated by multiplying the nameplate voltage by nameplate amperage, Watts = Volts X Amps.

If only the running voltage is given on the nameplate for a device with an electric motor, the starting wattage can be approximated to be three to five times the running wattage.

Estimates for the running wattage requirements for common devices are listed in Table 1 below. Guidance for starting wattages is provided in the table’s footnotes.

Table 1

Device

Air conditioner (12.000 BTU) 1700 (a,b) Jet pump 800 (a) Battery charger (20 Amp) 500 Lawn mower 1200 Belt sander (3”) 1000 Light bulb (100 Watt) 100 Chain saw 1200 Microwave oven 700 Circular saw (6½”) 2000 (a,b) Milk cooler 1100 (a) Coffee maker 1800 (a,b) Oil burner on furnace 300 Compressor (1 HP) 1400 (a,b) Oil-fired space heater (140,000 Btu) 400 Compressor (3/4 HP) 1800 (a) Oil-fired space heater (85,000 Btu) 225 Compressor (1/2 HP) 1400 (a) Oil-fired space heater (30,000 Btu) 150 Curling iron 700 Oven 4500 Dishwasher 1200 Paint sprayer, Airless (1/3 HP) 600 (a) Edge trimmer 500 Paint sprayer, Airless (handheld) 150 Electric nail gun 1200 Radio 200 Electric range (1 element) 1500 Refrigerator 600 (b) Electric skillet 1250 Slow cooker 200

attached electrical devices, and may result in fire.

running and starting wattage.

require a starting wattage that is 3 to 5 times greater than the running wattage.

Example conversion to watts:

120 Volts X 5 Amps = 600 Watts

Running

Watts Device

Running

Watts

Power Load Planning & Management (cont’d)

Device

Running

Watts Device

Running

Watts

Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a) Freezer 800 (b) Submersible pump (1 HP) 2000 (a) Hair dryer 1200 Submersible pump (1/2 HP) 1500 (a) Hand drill (1”) 1100 Sump pump 600 (a) Hand drill (1/2”) 875 Table saw 2000 (a) Hand drill (3/8”) 500 Television 500 Hand drill (1/4”) 250 Toaster 1000 Hedge trimmer 450 Vacuum cleaner 250 Home computer 150 VCR 70 Impact wrench 500 Water Heater 3000 Weed trimmer 500

(a) Hard-starting motors require 3-5 times the rated running watts (b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to

determine maximum wattage

To calculate the running and starting wattage requirements for the devices you will be powering, follow these steps:

1. Make a list of all electrical devices you will be powering at the same time with the generator.

2. List the greater of the running or starting wattage next to each device as obtained from the

devices’ nameplate or Table 1. If only the running wattage for a device with an electric motor is known, the starting wattage can be estimated to be at least 3 times the running wattage.

3. Add the wattages for all devices on your list. This total must be lower than the continuous output rating of your generator.

Example:

Device to be Powered

Light Bulb 75 W Refrigerator – 18 Cu. Ft. 1600 W Microwave 700 W Window AC 1800 W Sump pump (1/3 hp) 2100 W

Total 6275W

Greater of Starting/Running

Wattage

In this example, the generator must have a continuous output of at least 6275 W in order to power all of the devices simultaneously.

STAGGERING LOADS

You can increase the number of devices your generator can power by staggering the load on the generator. For example, you could alternately power your refrigerator and air conditioner for limited periods of time -- powering only one of the devices at a time and never powering both at the same time.

Installation / Initial Set-Up

There are a number of important steps required to set up your generator for initial use. These steps are:

Steps for Installation / Initial Set-Up

1. Unpacking & delivery inspection.

2. Planning the power load to stay within the generator’s rated capacity.

3. Setting up generator for the type of power generation you need:

a. portable power source, or b. connected to a building as a back-up power source.

4. Selecting a site for using the generator.

5. Grounding.

6. Battery installation (electric start models only).

Each of these steps is discussed in detail below:

1. Unpacking & Delivery Inspection

You should inspect the generator immediately after you receive delivery.

See the “Machine Component Identification” section of this manual for a

• If you have missing components, contact Product Support at 1-800-270-0810.

• If you have damaged components, contact the freight company that delivered the unit and file a

Plan your power load so that you do not exceed the generator’s rated capacity. See the “Power Load Planning & Management” section of this manual to review how to plan and

manage power loads for the generator.

diagram of the generator and its components.

claim.

2. Planning the Power Load

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 8000W of 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 accordance with building electrical code and guidelines supplied by your power company.

2. As a portable power source. You can plug appliances or tools directly into the generator’s

electrical outlets.

Specific requirements for each are given below.

Note: Regardless of whether you use your generator as a back-up power source connected to a

building or as a portable power source, you must not overload the generator. Overloading may cause serious damage to the generator and attached electrical devices.

Using as a Back-up Power Source for a Building

Contact a licensed electrician to install an UL-approved transfer switch if

you want to use your generator as a back-up power source for a building. What does a transfer switch do? It:

a) Safely connects the generator to your building’s electrical system by

isolating your generator from your utility company’s power lines, AND

b) Connects your generator to a critical subset of your building’s circuits

that are needed for emergency power needs.

If your generator will be connected to your building’s electrical system, it MUST ALWAYS be isolated from the utility power grid with a UL-approved transfer switch installed by a licensed electrician in compliance with all applicable building and electrical codes, and in accordance with guidelines supplied by your power company.

DANGER:

A transfer switch must be installed in order to isolate your generator from the utility power grid. If your generator is NOT properly isolated from the utility system, serious hazards will arise: ♦ When your generator is running, it’s output will back feed

into the utility power line and transformer that are normally used to provide you with power. The transformer will step up the current to the normal line voltage. An unsuspecting utility line worker working on what he thinks is a deactivated line could be electrocuted.

♦ If your generator is connected (running or not) when

utility power is restored, your generator will be destroyed. It could also explode or cause fire.

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.

. The transfer switch must be installed in

NEMA

Using as a Portable Power Source

Installation / Initial Set-Up

The generator cannot power your entire home -- you must work with the installing electrician to determine which devices/appliances you wish to power during an outage. The electrician can help you determine which circuits and devices can be powered simultaneously without overloading the generator.

(See the previous section of this manual entitled “Power Load Planning &

Management” for more information on load application and selection.) When using the generator as a portable power source, you can plug electric devices and appliances directly into the generator’s electrical outlets.

There are four different kinds of electrical outlets on the generator:

1. One 120 Volt, 50 Amp straight-blade receptacle (NEMA 5-50R receptacle compatible with NEMA 5-50P mating plug)

2. One 120/240 Volt, 30 Amp locking receptacle (NEMA L14-30R locking receptacle compatible with L14-30P mating plug)

3. One 120 Volt, 30 Amp locking receptacle (NEMA L5-30R receptacle compatible with NEMA L5-30P mating plug)

4. Two 120 Volt, 20 Amp, duplex GFCI-protected straight-blade receptacles (NEMA 5-20R duplex receptacles compatible with NEMA 5-20P or 5-15P mating plugs) – with a single, shared trip

Note: This generator is equipped with a Full Power Switch that allows you

light and reset button.

to switch between 120V only or 120/240V power at the outlets. See the “Machine Component Identification” section of this manual for more information about the use of the Full Power Switch.

IDLE CON TR OL

DJUSTABLE IDLE

DELA

HOUR METER

RECEPTACLES

EMA FULL POWER SWITCH

L14-30

EMA

L5-30

120V

EMA

5-50

5-20R

(See more technical detail about these receptacles and their associated circuit breakers in the “Machine Component Identification” section of this manual.)

+ 30 hidden pages

North Star 8000 IPG User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual