North Star M165912I.3 User Manual

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:

CO Poisoning

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 at least 20 feet from the home, away from windows, vents and air intakes, to allow

proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY. 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/buildings (battery-operated, 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.

Fire / Explosion

 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.

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.

ITEM NUMBER: 165912 SERIAL NUMBER: _____________

M165912I.3

Owner’s Manual

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

Portable, Outdoor Use-Only, Gasoline Generator

2,400 Watt Continuous (2,700 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.

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

Operation:

1. General Safety Rules for Operation ....................................................................................... 19

2. Preparing for Operation .......................................................................................................... 22

3. Starting the Engine ................................................................................................................. 25

4. Checking Generator Output .................................................................................................... 26

5. Connecting Loads ................................................................................................................... 27

6. Stopping the Engine ............................................................................................................... 27

7. Storage & Exercise ................................................................................................................. 28

Maintenance & Repair .................................................................................................................. 30

Troubleshooting ............................................................................................................................. 32

Summary of Important Safety Information for Operation ....................................................... 33

Generator Exploded View ............................................................................................................ 37

Wiring Diagram ............................................................................................................................. 39

Limited Warranty ......................................................................................................................... 41

About Your Generator

WARNING

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.

Thank you for purchasing your NorthStar portable generator!

About Your Generator

This engine-driven, portable generator is designed to provide up to 2700 Watts of electrical power (2400 watts continuous, 2700 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 vinyl 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

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.

About Your Generator (cont’d)

ATTENTION:

All Rental Companies and Private Owners who loan this

equipment to others!

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.

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.

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.

Specifications

SPECIFICATIONS

Item Number

#165912

Maximum Output

2700 Watts (W)

Continuous Output

2400 Watts (W)

Generator Type

Brushless

Voltage

120 Volt (V)

Phase

Single phase

Frequency

56.5 - 63.3 Hertz (Hz)

Power Factor

1.0 p.f.

Engine

5 Hp Honda GC160 AVXA

Engine Speed

3390 - 3798 RPM

Fuel Type

Unleaded gasoline

Fuel Capacity

2.12 quarts (2.0 L)

Oil Capacity

0.55 US quarts (0.52 L)

Starting Method

Recoil

120 V Receptacles

2, 20 Amp (A) duplex

(NEMA 5-20R)

Circuit Breaker

20 Amp (A) thermal, push to reset style

Dimensions

Length

23.00” (58.4 cm)

Width

15.75” (40.0 cm)

Height

15.75” (40.0 cm)

Dry Weight

80 lb (36 kg)

Gross Weight

88 lb (40 kg)

Safety Label Locations

PN 39260

BURN HAZARD

Do not touch hot muffler.

WARNING

Fig02663

On-Product Warning Labels

Part numbers

Description

39260

Burn Warning

779428

Warning

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.

Machine Component Identification – 165912I.3

Ref.

Description

Ref.

Description

Circuit Breaker

Choke Lever

120V 20A Duplex Receptacle

Ignition Switch Lever

Generator Head

Recoil

Oil Drain Plug

Gas Tank

Vibration Isolation Mount

Air Cleaner

Muffler

Figure 1 (Ref. 1-7)

Figure 2 (Ref. 7-11)

Machine Component Identification – 165912I.3 (cont’d)

REFERENCE GUIDE

Reference 1 – Circuit Breaker

This portable single phase generator has 1, 20 amp (A) push to reset circuit breaker to protect against electrical overloads.

Reference 2 – (2) 120V 20A Duplex Receptacles

The generator has a control panel with two 120V duplex (two receptacles in a common housing) receptacles. The duplex is a 120 volt (V) 20 amp (A) straight blade receptacle, National Electrical Manufacturer’s Association (NEMA) number 520R. This receptacle accepts NEMA plug numbers 5-15P and 5-20P. Each receptacle on the duplex is capable of drawing 20A.

Reference 3 – Generator Head

The electricity producing part of the generator.

Reference 4 – Oil Drain Plug

Refer to your Honda engine manual for oil change recommendations.

Reference 5 – Vibration Isolation Mount

The engine and generator 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 6 – Muffler

Honda’s standard muffler with an installed spark arrestor.

Reference 7 – Choke Lever

Used during cold starts. Refer to the Honda engine manual for usage.

Reference 8 – Ignition Switch Lever

The red engine stop lever is located on the engine. Always locate this lever and be familiar with its location before operating the generator.

Reference 9 – Recoil

Grasp firmly when pull starting the engine.

Reference 10 – Gas Tank

Always allow room for gasoline expansion by

not filling the gas tank completely full.

Reference 11 – Air Cleaner

Refer to your Honda engine manual for air cleaner care.

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.

Device

Running

Watts

Device

Running

Watts

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

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

running and starting wattage.

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

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

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.

Example conversion to watts:

120 Volts X 5 Amps = 600 Watts

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

Power Load Planning & Management (cont’d)

Device

Running

Watts

Device

Running

Watts

Electric range (1 element)

1500

Refrigerator

600 (b)

Electric skillet

1250

Slow cooker

200

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

Impact wrench

500

Water Heater

3000

Weed trimmer

500

Device to be Powered

Greater of Starting/Running

Wattage

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

STAGGERING LOADS

(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:

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

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

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.

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

diagram of the generator and its components.

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

2. Planning the Power Load

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.

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

Each of these steps is discussed in detail below:

Installation / Initial Set-Up (cont’d)

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

This generator is designed to provide up to 2700W 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. The transfer switch must be installed in 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 a 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.

+ 29 hidden pages

North Star M165912I.3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Specifications