NORTHSTAR Standby Generator Owner's manual

Brand: NORTHSTAR

Model: Standby Generator

Category: Power generators

Type: Owner's manual

Proven

ITEM #165952

MODEL 10500 SBG

Stand By Generator

Installation and Operation Manual

DANGER

ONLY A QUALIFIED CONTRACTOR OR ELECTRICIAN SHOULD INSTALL THIS PRODUCT.

IT MUST BE INSTALLED IN ACCORDANCE WITH APPLICABLE REGULATIONS, CODES,

AND STANDARDS.

M165952F

THANK YOU

Thank you for purchasing a NorthStar Standby Generator. Your machine is designed for long

life, dependability, and the top performance you demand. Please take time now to read through

this manual so you can better understand the generator installation, maintenance and safety

precautions. Everyone who installs, or maintains this generator must read and understand this

manual. The time you take now will prolong your generator’s life and prepare you for its safe

operation. Enjoy the exceptional performance of your NorthStar product.

IMPORTANT INSTRUCTIONS

Make certain:

- The operator and installer read and understand this manual.

- If any portion of this manual is unclear, or portions of this manual are missing please call:

NorthStar Customer Service at 1-800-270-0810

Monday - Friday, 7:00 AM to 5:00 PM, CST

Saturday 7:30 AM to 11:30 AM, CST

Throughout this manual and on safety decals located on the machinery, DANGER, WARNING,

and CAUTION headings are used to identify special instruction that must be understood prior

to installation, repair, or operation of this generator. Observe the DANGER, WARNING, and

CAUTION blocks carefully. Their definitions are as follows:

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.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in a

death or serious injury.

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.

After the DANGER, WARNING, and CAUTION headings, appropriate instructions are relayed

about specific functions or installation procedures that may be hazardous if the safety instructions

are not followed. HOW TO OBTAIN SERVICE

When your NorthStar product requires service or repair, simply call our NorthStar Customer

Service Department. We will locate the nearest authorized service center. Please call this

number:

NorthStar Customer Service

1-800-270-0810

Monday - Friday, 7:00 AM to 5:30 PM, CST

Saturday 7:30 AM to 11:30 AM, CST

NOTICE

NTE Manufacturing reserves the right to make improvements in design and/or changes in

specifications at any time without incurring any obligation to install them on units previously sold.

SAFETY RULES

! SAVE THESE INSTRUCTIONS !

It is strongly encouraged that the SAFETY RULES

be copied and posted near the generator

installation site and near the transfer switch.

The safety rules must be studied carefully prior to

installing, operating, or servicing this equipment.

Become familiar with both the Installation, Owner’s

Manual, and the actual generator set prior to

installation.

For trouble free operation and safety concerns,

NorthStar recommends that installation, initial start-up,

and maintenance should issues be addressed by

professionals who are familiar with installation and

operation of stand by generator sets.

DANGER • Never operate this generator in

an enclosed area. Exhaust gases contain carbon

monoxide, an odorless and deadly poison.

DANGER • Never install the generator in

such a location that exhaust gases can seep back into

closed rooms. Gases can seep into closed rooms

through windows, doors, and floors.

DANGER • Never install this product indoors,

or modify the exhaust system for indoor installation.

DANGER • Always disconnect the battery

prior to installation or servicing the generator or

transfer switch. This product can start

automatically. Disconnect the battery cable from the

NEGATIVE, NEG, or (-) terminal first. Reconnect that

cable last.

DANGER • Never work inside the generator

unless utility power is disconnected. Remember: The

battery charger and convenience receptacle are

energized by a 120-volt electrical circuit that is

independent of the stand by generator.

DANGER • Always remove the spark plugs

or spark plug wires before working on the engine or

generator. The engine can start automatically.

SAFETY RULES

ELECTRICAL HAZARDS

The generator covered within this manual can and

will produce dangerous electrical voltages that cause

fatal electrical shocks. The utility power that is

connected to the transfer switch produces extremely

high and dangerous voltages, as does the generator

set when in operation. Avoid any contact to bare wires

while the utility is energizing the transfer switch, and

avoid any contact with bare wires until the generator

set is disabled from auto/manual start.

DANGER • Never handle any kind of electrical

device while standing in water, while barefoot, or while

hands or feet are wet. Dangerous electrical shock will

result.

DANGER • The National Electrical Code (NFPA

70) requires the frame and externally conductive parts

of the generator to be connected to an approved earth

ground.

DANGER • This home stand by electrical system

may start without warning. When the generator starts

load circuits automatically can transfer by the transfer

swi tch . Never work on the home electrical system

without first disabling the starting mechanism of the

stand by generator set. Never work on the home

electrical system without first de-energizing the

incoming utility power at the main line circuit breaker.

FIRE HAZARDS

DANGER • Gas hookup must comply with the

Federal and Local jurisdictions for Liquid (LPG) and

Natural Gas (NG) codes. ALWAYS have a qualified

technician complete the LPG/NG hookup. Improper

installation can cause injury or death.

DANGER • LPG and NG are lethal and explosive

gases. If you smell gas, exit the area immediately.

DANGER • Do not smoke around the generator.

Wipe up any fuel or oil spills immediately. Ensure that

no combustible materials are left in the generator

compartment, or near the generator. Keep area

around the generator clean and free of debris. Keep a

fire extinguisher rated “ABC” near the generator.

Table of Contents

Introduction Page 1

Thank you Page 1

Important Instructions Page 1

How to Obtain Service Page 1

Notice Page 1

Safety Rules Page 2

Table of Contents Page 3

Section 1 - Specifications Page 3

1.1 Engine Page 3

1.2 Generator Page 3

1.3 Control System Page 4

Section 2 - Installation Page 4

2.1 Introduction Page 4

2.2 Assistance Page 4

2.3 Unpacking the Product Page 5

2.4 Installation Preparation Page 5

2.5 Generator Location Page 5

Sizing the Generator Slab Page 5

Generator Dimensions Page 6

Mounting Pad Design Page 7

2.6 Fuel System Introduction Page 8

2.7 Fuel System Components Page 8

2.8 Generator Winding Connections Page 9-10

2.9 Wiring Connections Page 10-11

2.9.1 A.C. Wiring Connections Page 11-12

2.9.2 Battery Charger Connections Page 12

2.9.3 Automatic Start Connections Page 13

2.10 Fuel Mixture Reconfiguration Page 13

2.11 Battery Introduction Page 14

2.11.1 Battery Warnings Page 15

2.11.2 Battery Size Page 15

2.11.3 Battery Installation Page 15

Section 3 - Component Identification Page 16

3.1 Control Box Components Page 17-18

Section 4- Theory of Operation Page 18-19

Section 5- Maintenance Page 19

5.1 Spark Arrester Maintenance Page 19

5.2 Oil Drain Valve Operation Page 19

Troubleshooting Page 20

Engine Wiring Harness Page 21

Electrical Schematic Page 22

Stand-By Generator Parts Explosion Page 23-24

Fuel System Parts Explosion Page 25-26

Control Panel Wiring Diagram Page 27-28

Section 1: Specifications

1.1 Engine

Manufacturer Honda

Model

Type GX620K1

VAF

Rated Horsepower 20 H.P. @ 3600rpm

Displacement

[Bore X Stroke] 37.5 cu-in (614 cc)

[3.03X2.60 in (77X66mm)]

Number of Cylinders 2

Cylinder Block Cast Aluminum

Valve Arrangement 4--Stroke, Overhead Valve

Ignition System Transistorized Magneto

Compression Ratio 8.3:1

Max Torque 32.5 lb-ft @ 2500 rpm

Cooling System Forced Air

PTO Shaft Rotation Counterclockwise

(viewed from PTO side)

Spark Plug Gap 0.028 - 0.031 in.

Recommended Spark Plug ZGR5A (NGK)

J16CR-U (DENSO)

Valve Clearance (cold) IN: 0.15 ± 0.02 mm

EX: 0.20 ± 0.02 mm

Oil Specifications Engine Owner’s Manual

Oil Capacity

Oil Capacity with Filter 1.59 US Quarts

1.90 US Quarts

Recommended Oil Filter

Honda # 15400-POH-305PE

Recommended Air Filter

Honda # 17010-ZJ1-000

Starter 12 Vdc, Solenoid Shift

Battery 12 Vdc, Negative Ground

Battery Size Group U1-7

Battery Amp-Hour Rating 45 Minimum

Battery Dimensions (l,w,h) 7.25”, 5.00”, 8.75”

Engine Charging System 12 Vdc, 20 Amp

1.2 Generator

Continuous Power (Watts) 9600 (LPG) / 8000 (NG)

Voltage (Volts) 120/240

Continuous Current (Amps) 40.0 (LPG) / 33.3 (NG)

Frequency Range (Hz.) 56.6 - 63.3

Power Factor (p.f.) 1.0

Main Line Circuit Breaker 120/240 Volt, 40 Amps

Phase Single

Rotor Poles 2

Insulation Class H

Windings 100% Copper

Nominal Operation Speed 3600 rpm

1.3 Control System

Battery Charger

Input Specification

Output Specification

Charging

Maintaining

115 Vac, 1.0 Amp

12.0 Vdc, 2.0 Amp

13.3 Vdc, 0.1 Amp

Battery Charger Fuse Bussman AGX 6

32Vdc, 6 Amp

1/4” X 1” Non-Time Delay

Convenience Receptacle 125Volt, 20 Amp, GFCI

Convenience Receptacle

Circuit Breaker 125 Volt, 20 Amp, Push

to Reset Style

Engine Controller

Voltage

Overspeed Shutdown

High Temp. Shutdown

Oil Pressure Shutdown

Over Crank Shutdown

12 Vdc

4080 rpm (68 Hz.)

300° F

14.22 psi (98 kPa)

3 Attempts at Starting

Engine Controller Fuse 12 Vdc, 20 Amp

ATO Series

(Automotive Style)

Fuel Lockoff Solenoid 12 Vdc.

Cooling Fan 12 Vdc.

Section 2: Installation

2.1 Introduction

DANGER • Only qualified electricians or

contractors should attempt installation of

either the stand by generator or transfer

switch. The installation must comply with all

applicable codes, regulations, or standards.

Note: Please read the entire manual before

attempting to install the stand by generator or

transfer switch.

NorthStar designs products that are safe to

operate and easily installed. We cannot predict all

installation procedures or methods required to

install our products. It is the installer’s

responsibility to follow safe work procedures, and

to correctly identify potential hazards while

installing this product.

2.2 Assistance

1: For Home or Business installation, a certified

electrician or contractor is required. To arrange

for proper installation, contact one of the

following sources:

• Electrical Contractors: Consult the local phone

book under the classification “ Electrical

Contractors”.

• Heating and A/C Contractors: Look in your local

phone book under the classification “ Heating

Contractors” or “Air Conditioning Contractors.”

• Call Customer Service at 1-800-270-0810

between the hours of 7:30 a.m. and 5:00 p.m.

CST. Our Customer Service Department will

assist in finding the nearest qualified installer.

2: For installation by a Certified Electrician or

Contractor: all required information is contained

within this manual for proper installation and

startup. If further information is required please

call Customer Service directly at 1-800-270-

0810 between the hours of 7:30 a.m. and 5:00

p.m. Our Customer Service Department will

assist in finding the nearest qualified installer.

2.3 Unpacking the Product

WARNING • NEVER stand underneath

this product while attempting to move or lift

this product. NEVER attempt to lift without

proper help and equipment.

Please handle your NorthStar Stand By generator

with care. The shipping carton cannot protect your

generator from damage due to bumping, dropping,

or collision. Always store the generator with the

proper side up. Do not stack other items on top of

the carton.

If possible, loss of contents or damage should be

documented at time of delivery. The person(s)

delivering the Stand By generator should note all

damage on the freight bill.

After unpacking the stand by generator, inspect all

contents for damage during shipment. If damage

is detected, contact the carrier for their damaged

claim procedures.

“Concealed Damage” is damage to the contents

that was not evident when the product was

delivered. This damage is discovered at a later

time. It is always prudent to take a photograph of

shipping damage.

Shipping Restraint

The stand by generator is delivered with a

shipping restraint to prevent damage. Remove the

bolt, spacer, and yellow tag located just below the

engine starter. Failure to remove shipping restraint

may cause damage to machine.

2.4 Installation Preparation

Prior to installation of this equipment check the

ratings of both the generator set and transfer

switch. The generator and transfer switch voltage,

amperage, and wattage must be adequate to

handle all electrical loads that the generator and

transfer switch will power. In some instances

critical or essential electrical loads will require

“grouping” together into a separate load panel as

the generator will not be of sufficient size to carry

all electrical loads.

CAUTION • Electrical and/or building

permits may be required in your area for

installation of a Standby generator. Check

your local codes for routing of gas lines and

noise ordinance allowances.

Fig. 01164 – Pallet Disassembly

The stand by generator is fastened to the shipping

pallet by four 1/4” X 1.5” lag bolts. A 1/2” wrench is

required to remove the lag bolts from the pallet

(Figure 01164).

2.5 Generator Location

DANGER • Never operate this generator in

an enclosed area. Exhaust gases contain carbon

monoxide, an odorless and deadly poison.

DANGER • Never install the generator in

a location that exhaust gases can seep back

into closed rooms. Gases can seep into closed

rooms through windows, doors, and floors.

Install the stand by generator set outdoors where

there is an adequate supply of fresh cooling air. To

help ensure trouble free operation, the following

suggestions should be considered:

1: Never install the generator in areas prone to the

collection of rainwater.

2: Never install the generator in an area that is

prone to flooding.

3: Never locate the generator on a roof.

4: Always locate the generator as close to the

transfer switch as possible. This will shorten the

length of electrical lead wire and conduit that is

required for the installation.

5: Always install the generator as close as

possible to the fuel source. This will help reduce

the length of pipe required for the installation.

ALWAYS consult your gas supplier, as they are

aware of laws and local codes governing the

placement of the gas pipe.

6: Always install the generator such that the air

inlets and outlets will not become blocked or

clogged with grass, leaves, litter, snow, or other

items. Clogged inlets or outlets will cause the

engine and generator to perform poorly, and

possibly result in equipment failure.

7: Always install the generator such that there is

adequate space on all sides for servicing and

performing maintenance. A minimum of 7 feet on

all sides should be adequate. REMEMBER:

LAWS OR CODES MAY DICTATE REQUIRED

DISTANCES FROM STRUCTURES OR FUEL

SOURCES.

2.6 Sizing the Generator Mounting Slab

The stand by generator must be mounted on a

mounting pad that adequately supports the

generator housing. External isolation mounts are

not required as the generator set has vibration

isolation mounts located between the engine -

generator and the base.

It is advisable to fasten the generator

compartment to a concrete mounting slab with a

quantity (4) of 1/4 - inch masonry type anchor

bolts. Check that the bolts are of sufficient length

to adequately secure the enclosure.

The concrete slab should extend past the

enclosure by a minimum of 3 inches on all sides.

The concrete slab must be level. For further

details concerning concrete slab dimensions and

details, see FIG 01168.

LAG BOLT

PALLET

FIG01164

Bolt

Space

Yello

Tag

FIG. 01165 - GENERATOR DIMENSIONS

FIG. 01168 - Mounting Pad Design

2.6 Fuel System Introduction

The following information is only to assist the

gaseous fuel technician with installation and set-

up. ALWAYS follow LOCAL and FEDERAL gas

codes when installing this product. Consult your

local fuel supplier or Fire Marshall if questions or

installation problems occur.

When installing the fuel system, place a flexible

length of fuel line between the generator fuel

connection point and the rigid piping. The section

of flexible fuel line must be approved for gaseous

fuel use, and meet the requirements as dictated by

LOCAL and FEDERAL gas codes.

It is advised that a manual fuel shutoff valve be

placed in-line with the rigid piping.

This product is designed to operate on either

Natural Gas (NG) or Liquid Petroleum Gas (LPG).

Only use a vapor withdrawal system to deliver fuel

to the engine. A vapor withdrawal system uses

the vapors that are formed on top of the liquid fuel.

Note: This engine only burns vapor fuel.

The fuel system is factory preset for NG. If the fuel

source is LPG, follow the fuel reconfiguration

directions in Section 2.10.

To achieve maximum horsepower from the

engine, the recommended fuels should have a

minimum BTU content of 1,000 BTU per cubic foot

for Natural Gas (NG) and 2516 BTU per cubic foot

for Liquid Petroleum Gas (LPG). See Table 1.5 for

fuel

LPG Conversion Factors:

1 lb. = 8.58 cubic feet

1 gallon = 36.39 cubic feet

Table 1.5 - Inlet Fuel Requirements

NG LPG

Pressure 4-6 oz. 7-11” Water Column

Flow 3.25 CFM 9.33 lb/hr, 2.2 gal / hr

BTU/HR 161374 201718

2.7 Fuel System Components

The fuel system is composed of four main

components: fuel lock off, demand regulator, load

block, and carburetor adapter. See Figure 01174.

The fuel lock-off is a safety device that

electrically operates with 12 Vdc. The valve is

open while 12 Vdc is present at its two electrical

terminals. If the engine should fail while

unattended, this device positively shuts off the flow

of fuel. The fuel lock-off has 3/4” NPT inlet pipe

thread, labeled “inlet”. This is the fuel inlet

connection point.

The demand regulator allows low-pressure fuels

to pass through if 4 ounces of vacuum is applied

to the outlet side of the regulator.

This device is sometimes called a “zero governing”

or “secondary”. The regulator is a vacuum

demand device, which is normally shut when the

engine is not running. Venturi vacuum causes the

secondary regulator to open and allow the flow of

fuel at a zero or negative pressure. This device is

not to be considered as a satisfactory fuel

lock-off valve, or a pressure regulator.

The load block is a device that adjusts the fuel

mixture. If this device is set incorrectly, the engine

will experience difficulty in starting, and cause

poor engine performance.

The adapter mounts between the engine

carburetor and the air cleaner. Inside the adapter

is a venturi. The venturi is a symmetrical restriction

that produces a pressure drop (vacuum) and

draws fuel into the air stream. The amount of fuel

drawn in is proportional to the volume and speed

of the air passing through the venturi.

FIG 01174 - Fuel System Components

VENTURI

ADAPTER

FUEL LOCKOFF

(fuel inlet)

DEMAND

REGULATOR

LOAD BLOCK

2.8 Generator Winding Connections

Figure 01175 represents a simplified pictorial of

the generator stator AC connection system. This

system is described as a 60-Hertz, single phase,

four-wire design. The generator stator produces

120/240 volts by means of two independent

stationary coil groups (windings), with two leads

brought out of each winding. Each winding can

nominally produce 120 Volts at 60 Hertz.

Combining both windings in series produces 240

Volts at 60 Hertz. Generator output leads 1 and 4

are ”HOT”. Generator output leads 2 and 3 are

“Neutral”.

Fig. 01175 - Generator AC Connection System

2.9 Wiring Connections

DANGER • Qualified electricians or

contractors should complete the wiring

connections. Follow all applicable electrical

codes, regulations, and standards.

CAUTION • Customer installed wires

designated as “power” lead should not be

mixed with “signal” leads in the same

electrical conduit.

CAUTION • The generator is configured

with a ‘bonded neutral” wire. The neutral wire

exiting the generator is bonded to the ground

circuit.

DANGER • Always disconnect the battery

prior to installation or servicing the generator or

transfer switch. This product can start

automatically. Disconnect the battery cable from the

NEGATIVE, NEG, or (-) terminal first. Reconnect that

cable last.

DANGER • Never work inside the generator

unless utility power is disconnected. Remember: The

battery charger and convenience receptacle may be

energized by a 120-volt electrical circuit that is

independent of the stand-by generator.

This generator is designed with a 3.25” diameter

hole in the base. This access hole allows for

routing of electrical conduit up through the

concrete mounting pad and into the generator

housing. See Figure 01168 (page 8). If the

installation does not allow the conduit to route

through the concrete pad, see the Right Side View

of Figure 01165 (page 7) for the area to locate

conduit elbows.

To complete the electrical connections, first

remove the (4) #10 socket head cap screws from

the lower cover plate. The #10 socket head cap

screws can be removed with a 5/32” hex key. See

Figure 01186.

Fig. 01186 - Generator Control Box

#10 SOCKET HEAD

CAP SCREWS

LOWER

COVER

PLATE

Route the electrical lead wires from the transfer

switch, through the grommets and into the

generator control box as pictured in Figure 01189.

Fig. 01189 - Routing of Lead Wires

2.9.1 A.C. Wiring Connections

All lead wires used for electrical connections

should be properly sized per the National Electric

Code (NEC). Always use stranded lead wire, and

NEC approved electrical conduit. When routing

lead wires into the generator housing and control

panel, check that sharp edges do not come into

contact with the lead wires.

To complete the electrical connections, route two

lead wires from the transfer switch connection

points marked E1 and E2 to the main line circuit

breaker (MCB) inside the generator set control

box. See Figure 01192 for the MCB location. Strip

1/2” of insulation from the ends of the lead wires.

Insert one wire into each circuit breaker

connection lug, and torque to 35 in-lbs.

Helpful Hint: Check that the lead wire has

adequate insulation removed prior to insertion into

the connection lug. A lead wire that is inserted

into a compression connection without adequate

insulation removed may create an open circuit .

Inside most transfer switches, the generator

contacts are designated as EMERGENCY

POWER, and labeled as connection points E1 and

E2.

Route the neutral wire from the transfer switch to

the generator control panel (Figure 01192). The

neutral lead wire shall only be connected to DIN

rail terminal block location #1. This terminal block

is rated for lead wire ranging from 22 AWG to 6

AWG. To install the neutral lead wire into the

terminal block, rotate the set screw

counterclockwise to open the funnel.

Fig. 01195 - Neutral Terminal Block

The set screw that opens the funnel is a size M4.

Strip adequate insulation from the NEUTRAL lead

wire and insert the lead wire completely into the

funnel (Figure 01196). Turn the set screw

clockwise to close the funnel. The set screw has a

torque specification of 16 inch-pounds minimum.

FROM TRANSFER SWITCH

(CUSTOMER INSTALLED)

LOWER COVER

PLATE

SET SCREW

CUSTOMER INSTALLED

(NEUTRAL WIRE)

SET SCREW

FUNNEL

Fig. 01196 - Neutral Terminal Block

FACTORY CONNECTIONS

CUSTOMER CONNECTIONS

LEAD WIRES TO THE GFCI RECEPTACLE

DO NOT DISTURB

LEAD WIRES TO THE GENERATOR HEAD

DO NOT DISTURB

MAIN LINE CIRCUIT BREAKE

LEAD WIRES TO ENGINE CONTROLLE

FOR REMOTE AUTOMATIC ENGINE START

DO NOT DISTURB

LOCATION #

DIN RAIL

CONNECTION LUGS- 35 IN-LBS TORQUE

EXTERNAL ELECTRICAL CIRCUI

TO POWER THE GFCI

RECEPTACLE AND BATTERY

CHARGER

“HOT” LEAD WIRE- 120V CIRCUIT

NEUTRAL LEAD WIRE

GROUND LEAD WIRE

LEAD WIRES TO TRANSFER SWITCH

“HOT” - TO TRANSFER SWITCH TERMINAL E1

“HOT” - TO TRANSFER SWITCH TERMINAL E2

NEUTRAL - TO TRANSFER SWITCH NEUTRAL

CONNECTION POINT

GROUND - TO TRANSFER SWITCH GROUND

LUG

Figure 01192 -Customer Field Wire Connections

REMOTE - AUTO STAR

Route the ground wire from the transfer switch to

the generator control panel (Figure 01192). The

ground lead wire shall only be connected to DIN

rail terminal block location #2 (Figure 01197). This

terminal block is colored GREEN and is rated for

lead wires ranging from 22 AWG to 6 AWG. To

install the ground lead wire into the terminal block,

rotate the set screw counterclockwise to open the

funnel (Figure 01198).

Fig. 01197 - Ground Terminal Block

The set screw that opens the funnel is a size M4.

Strip adequate insulation from the GROUND lead

wire and insert the lead wire completely into the

funnel (Figure 01198). Turn the set screw

clockwise to close the funnel. The set screw has a

torque specification of 16 inch-pounds minimum.

Fig. 01198 - Terminal Block

2.9.2 A.C. Battery Charger Connection

The battery charger is configured to plug into the

Ground Fault Circuit Interrupt (GFCI) receptacle.

This receptacle is located on the left side of the

control box (Figure 01199). The GFCI receptacle

is rated for 125 volts A.C. with a current rating of

20 Amps. The GFCI receptacle accepts either

NEMA 5-15P or NEMA 5-20P electrical plugs. A

125 volt, 20-amp circuit breaker, protects the GFCI

receptacle. If the circuit breaker trips, the black

post in the center of the circuit breaker will be

extended. Allow the circuit breaker to cool and

then press the black post back into the circuit

breaker. The circuit breaker is resettable, and is

located adjacent to the GFCI receptacle.

The battery charger electrical requirements are

115 Volts A.C. with a current rating of 0.8 Amps.

For the battery charger to operate, separate power

must be routed from the home to the generator set

by a separate circuit. Protect the wires with

electrical conduit. This separate circuit connects

into the control box at terminal blocks #2, #3, and

#4 (See figure 01192). Terminal block location #2

is designated for the Ground wire. Terminal block

location #3 is designated for the Neutral lead wire.

Terminal #4 is designated for the “hot” lead wire.

Insert the respective lead wires into the funnels

per Figure 01196.

FACTORY INSTALLED

(DO NOT DISTURB)

LOCATION #2

SET SCREW CUSTOMER INSTALLED

(GROUND WIRE)

SET SCREW

FUNNEL

CUSTOMER INSTALLED

UTO/OFF/MANUAL

SELECTOR SWITCH

2.9.3 Automatic Start Connections

This generator is equipped with a automatic

engine start feature. If it is desired to enable this

feature, the Auto/Off/Manual selector switch

(Figure 01199) is located on the control panel and

must be in the Auto position. The generator will

then start when terminals #5 and #6 (Figure

01192) are connected to a remote set of contacts.

The remote contacts must be configured as such:

close to start the engine, and open to stop the

engine. Generally, all transfer switches have a set

of remote engine start contacts. These contacts

close upon loss of utility power, and open once

utility power is restored. If your transfer switch is a

General Electric ZTX100 (Northern Tool &

Equipment item #165969) or General Electric

ZTX200 (Northern Tool & Equipment item #

165970) the engine start contacts are labeled as

X1 and X2 inside the transfer switch enclosure.

Refer to your Transfer Switch owners’ manual for

further information.

2.10 Fuel Mixture Reconfiguration

This generator set is designed to operate on either

Liquid Propane Gas (LPG) or Natural Gas (NG).

The fuel system was factory set for NG. If the

engine will not start, starts poorly, or requires

conversion to LPG, it may be necessary to adjust

the fuel mixture. To adjust the fuel mixture, locate

the fuel regulator assembly (Figure 01201). The

following tools are required to reconfigure the fuel

mixture: (1) 11/16” open-end wrench and (1)

straight blade screw driver.

Fig. 01201 - Regulator Assembly

The load block adjusts the fuel mixture that is fed into

the carburetor. To adjust the load block, loosen the

lock nut. The adjustment screw now can be turned

either clockwise or counter clockwise. While LPG or

NG is supplied to the fuel connection point (Figure

01174) put the Auto/Off/Manual selector switch in the

Manual position (Figure 01199) and slowly turn the

adjustment screw clockwise until the engine starts

(Figure 01202). Once the engine is running turn the

adjustment screw very slowly to smooth out engine

performance. Once the proper setting is achieved turn

the brass lock nut to secure the adjustment screw.

Fig. 01202 - Load Block Adjustment

FUEL REGULATOR ASSEMBLY

DJUSTMENT

SCREW

SCRE

DRIVER

11/16” WRENCH

DEMAND

REGULATOR

2.11 Battery Introduction

Installation or servicing the battery should only be

performed or supervised by personnel know-

legible about batteries and required precautions.

ALWAYS unplug the battery charger power cord

from the GFCI receptacle prior to installation or

removal of the battery. If the battery charger is left

plugged in, sparks will occur at the battery posts

as the battery cables are either attached or

removed. ALWAYS make sure the

AUTO/OFF/MANUAL selector switch is in the

OFF position prior to installation of the battery.

If the selector switch is in the AUTO or

MANUAL position during battery installation,

the engine may start. Always read the

following warnings prior to working on or

around the battery.

2.11.1 Battery Warnings

DANGER

• ALWAYS be sure that the utility power is

turned off to the battery charger, or sparks will

occur at the battery posts as the battery cables

are connected or disconnected.

• Always wear safety glasses.

•Shield eyes-explosive gases can cause

blindness.

•Sulfuric acid can cause blindness or severe

burns.

•Flush eyes immediately with water. Seek

medical help immediately.

•Never install or charge a visibly damaged or

frozen battery.

• Never dispose of a battery in a fire. The

battery is capable of exploding.

WARNING

• Spilled electrolyte or sulfuric acid is to be

washed down with an acid-neutralizing agent. A

common neutralizing agent is a mixture of 1 pound

of bicarbonate of soda to 1 gallon of water. The

resulting solution is to be applied to the acid spill

until evidence of reaction (foaming) has ceased.

Rinse the entire area with tap water and allow to

dry.

• Do not smoke when near the battery.

• Lead-Acid batteries present a risk of fire.

Batteries generate explosive hydrogen gas.

• Discharge static electricity from your body

prior to touching the battery. First, touch a

grounded metal surface.

ELECTRICAL HAZARDS

The battery can present a risk of electrical

shock from high electrical currents generated

from a short circuit. The following precautions

should ALWAYS be followed when working on

or near the battery.

• Disconnect power source from the battery

charger prior to connecting/disconnecting

electrical cables from the battery terminals.

• Remove watches, jewelry, rings, or other

metal objects.

• Never lay tool or other metal objects on top

of the battery.

• Wear rubber boots and rubber gloves.

2.11.2 Battery Size

The generator set is designed to operate on a 12

VDC negative ground system. The battery

compartment is sized for a Group U1 battery. A

Group U1 battery is sometimes referred to as a

“lawn and garden” style battery. See Figure 01203

for general dimensions and style of a Group U1

battery. Battery specifications are listed in Section

1.1.

Figure 01203 - Battery Dimensions

2.11.3 Battery Installation

The battery compartment is located behind an

access panel located on the front of the generator.

The access panel is removed by loosening the (4)

5/16 hex bolts with a 1/2” socket wrench (Figure

01204 and Figure 01205).

Figure 01204 - Battery Location

2.11.3 Battery Installation-Continued

When installing the battery, first review all of the

battery warnings in Section 2.11.1. ALWAYS

connect the positive battery cable first and the

negative battery cable last. The positive battery

cable should be connected to the RED,

POSITIVE, or “+” battery terminal. The negative

battery cable should be connected to the BLACK,

NEGATIVE, or “-” battery terminal.

Figur

e 01205 - Battery Installation

The battery charger has two leads, one red and

the other black. These two leads should be

connected to their respective locations on the

battery. The positive battery charger cable is

colored RED and is labeled “+”. There is also an

inline fuse and fuse holder associated with the

RED battery charger lead. The negative battery

charger cable is colored BLACK and should be

connected to the BLACK, NEGATIVE, or “-”

battery terminal. See Figure 01206.

WARNING • Disconnect power source

from the battery charger prior to connecting or

disconnecting electrical cables from the

battery terminals.

Failure to disconnect the incoming power from the

battery charger may cause a spark during

connection of either the battery cables or battery

charger cables. Sparks can ignite hydrogen or

other gases. Hydrogen is a gas vented from

batteries during charging.

Figure 0120 - Battery Installation

END OF SECTION

(4) 5/16” HEX BOLTS

FUSE

RED CABLES BLACK CABLE

Section 3:

Component Identification

Reference 1: Battery Compartment Cover

Plate. The battery compartment is located behind

the cover plate. The cover plate is secured with

four bolts.

Reference 2: Fuel Inlet. The fuel inlet is the fuel

connection point between the generator set and

the fuel delivery pipe. The fuel inlet is tapped for

3/4” NPT pipe. Always use a section of approved

flexible gas pipe between the fuel inlet and rigid

gas pipe.

Reference 3: Door and Door Lock. There are

two locking doors. The doors are designed to lift

completely out of the housing. To open the door,

press the key lock portion of the door latch. Each

door can be locked with the provided keys. Two

sets of keys are included with the generator.

Reference 4: Spark Arrester. The exhaust

system incorporates a removable spark arrester.

The spark arrester is a safety feature that insures

that sparks will not exit the muffler and cause a

fire. The spark arrester is USDA approved. The

spark arrester should be cleaned after every 50

hours of engine use. See Section 5.1of this

manual for further details.

Reference 5: Generator Head. The electricity

producing portion of the generator.

Reference 6: Dipstick. Use the oil dipstick to

monitor the engine oil level. Consult the Honda

engine owners’ manual for further information.

Reference 7: Remote Oil Drain and Plug. The

remote oil drain provides a clean and convenient

method to change engine oil.

Reference 7: (Continues) The oil drain plug

prevents accidental loss of engine oil. A 5/16” hex

key (Allan Wrench) is required to remove the oil

drain plug.

Reference 8: Engine Oil Drain Valve. The

engine oil drain valve provides a convenient

method to change oil. By opening the valve engine

oil flows to the remote oil drain (Reference 7).

Reference 9: Demand Regulator Assembly.

Supplies LP or NG fuel at a negative pressure

when the engine is running. The regulator is

sometimes referred to as a Secondary. The

Secondary regulator gauges the fuel flow or

amount of fuel delivered to the engine.

Reference 10: Engine. The engine is a 20 H.P.

Honda GX620 K1VXA. Refer to the Honda engine

owner’s manual for maintenance intervals. Refer

too Section 1.1 of this manual for general engine

information.

Reference 11: Battery Charger. The battery

charger is of a “3-stage” electronic design. The 3

charging stages are bulk, absorption, and float.

This charger is not of the “trickle” design that can

boil off the electrolyte and destroy a battery. The

battery charger plugs into the GFCI convenience

receptacle, which is located on the control panel.

When the battery charger is operating, a green

LED light on the front of the charger will be lit.

Reference 12: Spark Plug. The Honda engine

has two spark plugs. One is located on each side

of the engine. Refer to the Honda engine owners’

manual for maintenance.

Reference 13: Engine Oil Fill Cap. Remove cap

to add oil to the engine. Refer to the Honda engine

owners’ manual for oil recommendations.

Reference 14: Engine Air Cleaner. Refer to the

Honda engine owners’ manual for air cleaner

maintenance.

Reference 15: Control Box. Refer to Section 3.1

(page 18) for detailed information.

3.1 Control Box Components

START SWITCH

OFF

RESET

HOUR METER

AUTO

10500 SBG

TANDBY

ENERAT

Reference 16: Main Line Circuit Breaker. The

main circuit breaker is a 2-pole design that

protects the generator from electrical overloads. If

the circuit breaker trips, reset the breaker by

moving the lever to the OFF position and then

back to the ON position.

Reference 17: ON/OFF/AUTO. This switch will

start the engine if placed in the ON position. When

the switch is in the AUTO position, the generator

will start when the transfer switch senses loss of

utility power. The OFF position shuts down the

engine.

WARNING • With the switch set in the

AUTO position, the engine can crank and start

without warning. Automatic starting can occur

with loss of normal utility power or during a

normal exercise initiated by the transfer

switch. To prevent accidental engine starting,

place the switch in the OFF position and

disconnect the battery prior to working on or

around the generator.

Reference 18: Maintenance Interval Reset

Switch. The maintenance interval meter can be

instantly reset to zero by depressing the switch.

Reference 19: Total Hour Meter. The total hour

meter measures hours the engine has

accumulated while running. This portion of the

meter cannot reset.

Reference 20: Maintenance Interval Meter.

The lower meter is a maintenance interval meter.

It is used to measure hours between scheduled

maintenance. To reset this meter, depress the

maintenance interval reset switch (Reference 18).

This meter provides a convenient way to monitor

oil change intervals.

Reference 21: System Controller. T he system

controller starts, stops, and monitors the generator

set. There are five alarm lamps associated with

the engine controller. Their functions are as

follows:

Low Oil Pressure- In the event of low engine oil

pressure, the “low oil pressure” lamp will glow red,

and the engine will shut down. To reset the system

controller, place the ON/OFF/AUTO switch in the

OFF position. Check the engine oil level.

High Temperature- In the event of high

temperature, the “high temperature” lamp will glow

red, and the engine will shut down. To reset the

system controller, place the ON/OFF/AUTO switch

in the OFF position. Check for leaves or debris

blocking air inlets and outlets.

High Engine Speed- The system controller will

shut down the engine in the event that the engine

operating speed exceeds 4080 rpm for 5 seconds.

The “engine over crank” lamp will glow red. To

reset the system controller, place the

ON/OFF/AUTO switch in the OFF position.

Engine Over crank- The system controller will

engage the starter for 15 seconds. If the engine

does not start, the system controller will allow the

starter to cool down for 15 seconds, then attempt

to start the engine again. This process will repeat

three times. If the engine does not start after the

third attempt, the red “engine over crank” lamp will

glow. To reset the system controller, place the

ON/OFF/AUTO switch in the OFF position.

System Normal- This lamp indicates everything is

normal. The lamp will glow while the unit is

running, or in automatic mode.

3.1 Control Box Components

Reference 22: GFCI Receptacle. The GFCI

(ground fault circuit interrupter) duplex receptacle

is different from a conventional receptacle. In the

event of a ground fault, the GFCI will trip and

quickly stop the flow the flow of electricity, to

prevent serious injury. A ground fault is defined as

a condition where electricity does not follow its

normal path, but passes through a person’s body

to reach ground. A defective power tool can cause

a ground fault.

The GFCI receptacle designation is a NEMA 5-

20R, and will accept either a NEMA 5-15P or a

NEMA 5-20P electrical plug. This receptacle is

powered from a separate circuit-not the generator,

and will not work during a utility power outage.

This receptacle is rated for 125 volts at 20 amps

and will power most portable hand tools.

Reference 23: GFCI Test Button. This button

tests the operation of the GFCI receptacle. When

pressing the TEST button, the receptacle will trip.

Then press the reset button to reactivate the

GFCI. Test the GFCI receptacle every month.

Reference 24: Circuit Breaker. A 125-volt, 20-

amp push to reset circuit breaker protects the

GFCI receptacle. If this circuit breaker trips, the

black center post will be extended. Allow the

circuit breaker to cool for 1 minute and press the

black post beak into the housing.

Reference 25: GFCI Reset Button. If the GFCI

trips, press the reset button to reactivate the

receptacle.

Section 4

Theory of Operation

When starting the 165952A generator in manual

mode (Section 3, Reference 17), the following

sequence of events occur:

1: 12 volts (dc) is delivered from the battery “+”

terminal on the engine starter to the on/off/auto

three position switch located on the control panel

via lead wire “012” which is located inside the

engine wiring harness.

2: If the three position switch is in the manual

mode, 12 volts (dc) is then delivered to the system

control board which is located inside the control

box via lead wire “01A”.

3: Simultaneous to delivering 12 volts via lead wire

“01A” the three position switch closes a circuit

between lead wires “06A and 07”. The closure of

lead wires “O6A and O7” tells the system

controller to send 12 volts (dc) to the engine start

solenoid via lead wire “O3”. Lead wire “O3” is

located inside the engine wiring harness.

Trouble Shooting Hint: When the system control

board inputs (leads “O7 and O6A”) are connected

together, the engine will attempt to start if 12 volts

is present between lead wires “01A” and “G2B”.

System Control Board

4: At the same time the engine is cranking, both

the LP/NG fuel lock off valve and compartment fan

are energized by 12 volts via lead wire “O4”. Lead

wire “O4” exits the control box inside the engine

wi ring harness.

5: As the engine cranks, the pistons create

vacuum. The vacuum will influence the secondary

gas regulator to open and allow fuel to flow. The

secondary regulator reacts to a minimum of 4

ounces per square inch of vacuum.

Trouble Shooting Hint: It is crucial to have both

correct gas inlet pressure and fuel mixture for

quick starting. There is a 1/8” NPT port on the side

of the regulator that provides a convenient point to

measure inlet pressure.

6: As the engine comes up to operating speed

(3600 rpm), the engine continually sends an

electrical signal through a black with red stripe

lead wire that exits the engine. The black with red

stripe lead wire is connected into lead wire “O5A”.

Lead wire “O5A” is located inside of the engine

wiring harness and terminates at the system

control board. The importance of this signal is that

once a stable frequency is measured from the

magneto, the system control board takes the

engine starter off line. Secondly, if the frequency

exceeds 4080rpm for a time interval of 5 seconds

or greater, the system control board will alarm and

shutdown the engine down as a result of an over

speed condition.

7: During start up, the control board disregards low

oil pressure for 15 seconds. If after that period of

time, oil pressure has not developed, the system

control board will alarm and shut down the engine

as a result of low oil pressure.

1/8” NPT PORT

The oil pressure sender is located on the muffler

side of the engine, and is connected to the system

controller via lead wire “O9”. The oil pressure

sender is normally closed when the engine is not

running. A normally closed sender will complete

an internal circuit to the engine block, which is the

system ground. An ohmmeter is useful for

checking if the sender is functioning correctly.

Trouble Shooting Hint: If lead wires “G8 and O9”

are connected together, the system control board

will always shut down the engine as a result of low

oil pressure. Lead wire “G8” is a system ground

wire, and if the oil pressure sender is closed, lead

wire “O9” will be connected to ground.

8: The system control board can shut down the

generator at any time due to high engine

temperature. A high temperature condition is

monitored by a thermo-disk mounted to the

engine. The thermo-disk is normally open and

closes if the compartment air temperature

becomes excessive. The thermo-disk is connected

to the system control board via the two lead wires

“O10 and O11”.

Trouble Shooting Hint: The system control board

will shut down the engine if lead wires “O10 and

O11” are connected together. If the thermo-disk is

closed, lead wires “O10 and O11” are connected

together.

Section 5

Maintenance

To insure reliable and trouble free operation of

your stand by generator, it is important to follow

recommended maintenance schedules. Consult

your Honda engine owner’s manual for

maintenance schedules.

5.1 Spark Arrester Maintenance

The spark arrester should be removed and

cleaned with a wire brush every 50 hours of

engine operation.

1: Remove the setscrew and clean it with a

brush.

2: Pull the spark arrester out of the outlet

tube.

3: Clean the screen assembly with a wire brush.

If breaks in the screen are discovered, the

screen assembly must be replaced.

4: Return the screen assembly to the muffler

outlet tube and refasten with the set screw.

Muffler Assembly

Spark Arrester

5.2 Oil Drain Valve Operation

The engine oil drain valve can be opened with

either a 10mm metric socket, or a pair of pliers.

Simply turn the valve counterclockwise to open the

valve. Turn the valve clockwise to close.

SET SCRE

SPAR

ARRESTER

MUFFLE

OUTLET TUBE

SCREEN

VALVE

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NORTHSTAR Standby Generator Owner's manual

Brand: NORTHSTAR

Model: Standby Generator

Category: Power generators

Type: Owner's manual

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NORTHSTAR Standby Generator Owner's manual

NORTHSTAR Standby Generator Owner's manual

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