Northern Industrial Tools Portable Generator 10000 BDG User Manual

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  
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 1.75key 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 ftlb.  
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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