Scott Richey GenSTART Starting Module

Product Engineer
Active Power
Theory of Operations
2128 W. Braker Lane, BK12
INTRODUCTION
Austin, Texas 78758
The GenSTART starting module provides reliable power to a generator set
512-744-9412 engine’s starting motor. Almost all generator sets depend on batteries for
srichey@activepower.com cranking power. However, the number one reason for start failures of standby
generator sets is dead starting batteries. GenSTART is installed in parallel
with batteries or replaces batteries completely, to ensure the generator engine
cranks to a successful start at the critical time of a power event. In addition,
the system can even be configured to warn of other equipments failures that
might prevent emergency power from getting to the critical load. GenSTART’s
simple robust design will provide many years of superior reliability with minimum
maintenance or other recurring costs.

Configuration Overview
GenSTART converts three-phase AC voltage into 24 VDC that delivers 1725
cold cranking amps to the starting motor. The diagram below shows how
GenSTART is installed in typical applications. Three-phase AC voltage is taken
from the UPS output. The GenSTART module creates a balanced, three wire,
transformer coupled, non-linear load of about 30 KVA on the UPS when the
generator set is cranking. This load lasts about 3 to 5 seconds with the first
0.1-seconds being at the full load. After that point, the load diminishes as RPM
increase. Newton’s first law of motion explains this sequence of events. The
starter motor must overcome the resting inertia of the engine’s rotating assembly
at the start of the cranking cycle. Once the engine starts to crank, the resistance
to rotation reduces and the load decreases. A transformer within the GenSTART
enclosure steps down the 3-phase AC voltage. Next the 3-phase voltage is
diode rectified and filtered to 24 VDC.

Figure 1
GenSTART Installation Configuration
Any existing starting batteries can be installed in parallel to provide redundancy. All paralleling hardware
is contained within the GenSTART enclosure. The batteries are isolated from the GenSTART system
by an internal diode to allow continued charging by the existing battery charging system. The
GenSTART and batteries are combined in the single output of the GenSTART enclosure to be connected
to the starting motor.

Installation & Operations

GenSTART can be installed by wall mounting or on the floor with optional floor stands. The UL rated
outdoor enclosure allows for weatherproof operations. Once installed, GenSTART has no special
operating procedures or requirements; the system provides reliable operations without intervention.
Designed for 15 start cycles of 10 seconds each with 10 seconds between start attempts, it will
perform long after the starter motor fails or the genset prevents another start attempt. It will operate
in 50°C ambient temperatures and still provides full rated power and cycles. GenSTART can also
supply power to a 30-amp load at continuous operations if required.

GenSTART is designed to increase the reliability of the generator set’s starting system to ensure a
successful cranking cycle of the generator engine. Therefore, status contacts within GenSTART can
be connected to building monitoring systems. The contacts provide status of the output voltage
provided to the engine starter motor. If any upstream component fails and power is removed from the
starting motor for any reason, GenSTART can provide a notice to facility personnel.

Actual starting performance of GenSTART is explained below. The following oscilloscope trace is a
generator set starting sequence using the GenSTART starting module. The scope trace shows the
voltage and current delivered to the starting motor over a ten second period. In this close-up view, the
solenoid action can be seen at the beginning of the start sequence. Next the current rises to 1575
amps as the starter motor overcomes the resting inertia of the engine. Notice that as the engine
cranks, the current rapidly drops off from the maximum. For the first part of the start engagement, a
small current peak occurs when a compression cycle is encountered in the cranking sequence. After
this peak, the engine continues starting and the current required decreases further and goes to zero
when the starter motor stops.

Figure 2
GenSTART powered Cranking Cycle on a Caterpillar XQ-350 Diesel Generator Set
Maintenance
The GenSTART starting module needs no special maintenance. The system is designed to be robust
in outdoor environments. A yearly visual inspection should be done with the generator set maintenance.
An input power disconnect handle is provided on the front of the unit for isolation during maintenance.
If starting batteries are parallel, they will still be able to supply power to the starting motor.

Specifications

STARTING MODULE SPECIFICATIONS

Input Voltage 380-480 VAC, 3-phase 50/60 Hz
Nominal Output Voltage 24 VDC
Nominal Output Current Rating 1000 Amps
Cold Cranking Amps 1725 Amps
Rated Number of Start Attempts 15 cycles of 10 seconds each with 10 secondsbetween attempts
Distance from Generator Set Starter < 25 ft. (Refer to Generator Set Manual)
DC Cables Size for 1% maximum loss at 1000 Amps
Outdoor Installation UL Outdoor Enclosure Rating, NEMA 3
Temperature Range -20°C to 50°C
Heat Dissipation at Standby 1,025 BTU
Dimensions (W x H x D) 34" x 29" x 14.7" (865.9 mm x 736.6 mm x 374.1 mm)
Weight 300 lbs (136 kg)
Input Disconnect Standard
Thermal Protection, Auto Reset Standard
Remote Status Monitoring Output Standard
Wall Mount Standard
Battery Paralleling Capability Optional
Floor Mount Adaptor Optional
Generator Set Engine Starter Not included
2128 W. Braker Lane, BK12 • Austin, Texas 78758 • ph. 512/836-6464 • fx. 512/836-4511 • www.activepower.com