The Blackhawk 325 Amp Starter Generator offers improved

engine starts over the factory offered 200 Amp starter generator,
and 325 Amps of continuous power for the aircraft and specific
payloads. These improvements are offered with now limitations
for operating the aircraft, from ground to service ceiling.
The starter generator is mounted on the top of the accessory case
at the rear of the engine. It is a 28 volt, 325 Amp engine-driven
unit that functions as a motor for engine starting and as a
generator for the aircraft electrical system. When operated as a
starter, a speed sensing switch in the starter-generator will
automatically shut down the starter, providing overspeed
protection and automatic shutoff. The starter-generator is air
cooled with an integral fan and ram air from the engine cowling.
System Description
 

The 325 Amp Starter Generator system operates in exactly the same manner as the stock 200 Amp system and the factory
optional 300 Amp system. The 325 Amp Starter Generator produces faster spin-up of the gas generator due to its increased
current capacity, resulting in lower starting ITTs. All procedures remain unchanged.
The cooling air blast tube is increased to 3” diameter and air remains taken from the oil cooler inlet. There are no additional
air inlet(s) from the exterior of the cowling on the Blackhawk XP42A upgrade. The wire harness from the SG to the
Electrical Power Distribution Box (EPDB) has been increased from the OEM 4 gauge (2 gauge for the optional 300 Amp
system) to its present 0GA. The bus bars internal to the EPDB have been changed to permit use of MIL standard shunts in
lieu of the OEM proprietary shunts. The original shunts were rated to 300A, the new Blackhawk shunts are rated to 500A.
Lastly, the volt/ammeter has been changed to reflect the new current capacity. The overall system weight increases by 21.0
lbs. The increased overhang moment of the new Starter Generator is within the limits of the Starter Generator accessory
pad and the increased power extraction has been evaluated and only affects operation when full available torque is not
available (high, hot conditions).
This new 325A system does not have operational limitations; from an operational perspective, pilot should monitor ITT
during ground operation. An increase of Ng from Low Idle to High Idle is prescribed if the displayed ITT approaches 750°C
(PWC engine limitation). The full rated 325A electrical power capacity may be used during ground and flight operations.
Performance
As indicated in the previous sections, the full output of the Blackhawk 325 Amp Starter Generator is available for all
operating environments, including both ground and air. This capability has been demonstrated in developmental and
certification tests under the stringent conditions established by the Federal Aviation Administration for engine and engine

 
  16 September, 2014
 
component cooling (Advisory Circular AC 23-8C, Chapter 3, Section 5.3). The test methodology prescribes an intense
ground/flight profile, testing or empirically correcting data to the prescribed “100°F day”. For our tests, Blackhawk tested
in an atmosphere that was at or above 100°F on the ground.
During the test, the Blackhawk test aircraft commenced the ground portion with application of the full starter generator
output after battery top off (charging current below 10 Amps). The engine was set to high idle with the engine condition
lever. Sitting directly crosswind to the prevailing wind, the aircraft was operated at full load in excess 0d 20 minutes.
After the ground run, the aircraft was climbed at the best rate of climb speed (VY) until service ceiling was reached. After
a brief loitering at the service ceiling, the aircraft descended back to the airport and landed. During the descent, a level off
and a simulated missed approach was included within the profile. All of these 3 condition were accomplished with the full
325 Amp load applied to the starter generator.
The starter generator and its cooling system behaved exceptionally well. At the end of this document are time history figures
of the final cooling test. The temperature of five primary Starter Generator components was recorded, along with the cooling
exhaust air temperature (Outlet). All primary engine parameters, along with air data and the electrical load state of the
aircraft we also included. The significance of this test is best illustrated with the following table:
Component Allowed 
Starter Generator  Peak Test  Maximum Continuous  Temperature 
Component  Temperature  Temperature  Margin 
  °F  °F  °F 
Drive Bearing (A)  286.4  350  63.6 
COM Bearing (B)  190.5  350  159.5 
+ Brush (C)  381.3  450  68.7 
‐ Brush (D)  369.3  450  80.7 
Interpol Winding (E)  227.4  375  147.6 
 

By test, the Starter Generator system of the Caravan demonstrates considerable temperature margin on all critical
components for the 100°F day condition. Excess margin provides excess capability for age and for conditions potentially
more severe than the test conditions.
Future
More performance potential is presently designed into Blackhawk Starter Generator system. The Starter Generator design
used in our Caravan has successfully demonstrated 400 Amp output in FAA approved installations. Blackhawk has sized
the components of the Caravan to carry and monitor a 400 Amp load. Blackhawk will soon be evaluating this capability
and establishing the guidelines for use of the extra potential.
Beyond our Caravan installation, our 325 Amp Starter Generator is directly applicable to the Beech King Air 200 and 350
lines of aircraft. The Starter Generator system can provide the same benefit to those aircraft, including cooler, faster starts,
and excess electrical power for additional needs.

 
  16 September, 2014
 
Starter Generator Comparison
OEM Stock  OEM Optional  Blackhawk 
200 Amp  300 Amp  325 Amp 
100°C Cooler than
Start ITT  ---- ----
OEM 200 Amp
105 Amp limitation at
Ground  No Limitation up low ground idle NG No Limitation up
Operations  to 200 Amp 170 Amp limitation at to 325 Amp
high ground idle
250 Amp limitation if
No Limitation up No Limitation up
Flight Operations  above FL180 and lower
to 200 Amp to 325 Amp
than 100 KIAS
Weight  ---- +13.7 lb +19.9 lb
Cable Harness Size  4 Ga 2 Ga 0 Ga
Total/Future 
200 Amp 300 Amp 325/400 Amp
Capacity 
2000 hour claim, 1000 hour claim, 400 1500 hour “no
TBO 
400 actual actual touch”

 
  16 September, 2014
 290

280

270

260

250

240

230

220

210

200
Temperature (°F)

190

180

170

160

150

140

130

120

110

100

90

80

70

60

Time (sec)

400

4500 ft Hold
380

Shutdown
Liftoff

360

Descent
Peak Altitude
340

Descent
320
Takeoff Roll

300

280

Touchdown
Missed Approach
260
Temperature (°F)

Load Removed
240

220

200

180

160
325 Amp Load

140

120

100

80
Start

60

Time (sec)

320

300

280

260

240

220
Temperature (°F)

200

180

160

140

120

100

80

60

40

Time (sec)

Aircraft: Cessna 208B Average Ground Ambient

100.4 °F
Test Description: Cooling Climb Profile
Registration: N90GL Temperature:
Engine: PT6A-42A 325 Amp Starter Generator
Date of Test: 10-Jul-14 Maximum Gross Weight

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 2500

2000
Torque (ft-lb)

1500

1000

500

Time (sec)

100

80

60
NG (%)

40

20

Time (sec)

2500

2000

1500
NP (RPM)

1000

500

Time (sec)

800

600

400
ITT (°C)

200

Time (sec)

90

80

70
Oil Temperature (°C)

60

50

40

30

Time (sec)

140

120

100
Oil Pressure (°C)

80

60

40

20

Time (sec)

700

600

500
Fuel Flow (lb/hr)

400

300

200

100

Time (sec)

Aircraft: Cessna 208B Average Ground Ambient

100.4 °F
Test Description: Cooling Climb Profile
Registration: N90GL Temperature:
Engine: PT6A-42A 325 Amp Starter Generator
Date of Test: 10-Jul-14 Maximum Gross Weight

9/16/2014 14:32
 120

100
OAT

80
Temperature (°F)

60

40

20

Time (sec)

24000

22000

20000
Pressure Altitiude
18000

16000
Pressure Altitude (ft)

14000

12000

10000

8000

6000

4000

2000

Time (sec)

180

160

140 Calibrated Airspeed

120

100
Calibrated Airspeed (t)

80

60

40

20

Time (sec)

350 29

300 27

250 25

Generator Voltage (VDC)

Gneratore Current (Amp)

200 23

Bus Current
150 21
Bus Voltage

100 19

50 17

0 15

Time (sec)

600 600

Fuel Used
500 500
Fuel Flow
Fuel FLow (lb/hr)

400 400
Fuel Used (lb)

300 300

200 200

100 100

0 0

Time (sec)

Aircraft: Cessna 208B Test Description: Cooling Climb Profile

Registration: N90GL 325 Ambient Temperature: 100.4 °F
Engine: PT6A-42A 325 Amp Starter Generator
Date of Test: 10-Jul-14 Maximum Gross Weight

9/16/2014 14:32