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Kohler - Sizing Gensets For Motor Starting
Kohler - Sizing Gensets For Motor Starting
preload and nonlinear loading – make Motor loads cause difficulty because a
manual genset sizing difficult, if motor draws high current when started
not impossible. at full voltage. Starting current is typically
six times a motor’s rated full-load current,
Not only is sizing an application and this inrush current stays high until the
with large motors complex, but motor reaches about 75 percent of rated
different genset manufacturers have speed. When a motor is started on normal
different approaches for specifying utility power, the high inrush current will
a standby power system that cause only a small voltage dip because
will function reliably. Each major the utility is a more robust voltage source.
genset manufacturer has created However, when a motor is started on
genset-sizing software to help genset power, the high inrush currents
with this complex task, but due to (measured in kilovolt-amperes or KVAs) can
manufacturers’ differing approaches result in a large voltage dip that can inhibit
to motor starting, this software the motor from reaching its
can yield quite different results – operating speed.
sometimes specifying a larger and
more expensive generator or too small The challenge, then, is to size the genset
a generator than is necessary for to handle the motor-starting load, but also
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Line Circuit
Start
Start steps occurs.
2 2
Part-winding starters – Part-winding
Run Run
starters are used with motors that have two
Time Time
identical windings intended to be connected
Figure 4: Closed Transition
Figure vs. Open
4. Closed Transitionvs.
Transition Starters
Open Transition Starters in parallel. These windings can be energized
Source: Kohler Power Systems
in sequence to provide reduced starting
torque than the motor can develop at
current and torque. Since part-winding
reduced voltage, which prevents the
starters are inherently closed-transition
motor from reaching full speed. Additional
starters, the maximum inrush current occurs
consequences could include tripping of
at the moment the first winding is energized,
breakers or overheating of the motor. To
and the maximum inrush KVA load on a
ensure proper motor starting in these
genset set will be reduced to 60–70 percent
applications, it is necessary to compare the
of normal.
torque curves of the pump and the motor at
See Figure 5.
reduced voltage.
Autotransformer starters – This type
of starter provides reduced voltage at
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POWER SYSTEMS topics 103
the motor terminals from a tapped 3-phase 33 percent of the delta connected values. Use
autotransformer and generally gives the best only with closed-transition starters, however.
results with gensets. See Figure 6. Taps on See Figure 7.
the transformer provide selection of 80, 65 or
50 percent of initial line voltage to the motor Factors affecting real-world
motor starting
terminals. Starting torque is reduced by the
voltage squared to give 64, 42 or 25 percent Genset frequency dip – The genset’s engine
of the full-voltage value, respectively. To avoid cannot be ignored in motor starting due to
reducing starting torque to unacceptable levels, the high horsepower demanded when a large
use either the 80 or 65 percent taps. motor is started. When the engine slows under
load, frequency dips; this, in turn, increases
Solid-state (soft-start) starters – This
the alternator voltage dip. The amount of
type of starter is most popular and provides
impact on engine RPM during motor starting is
exceptional operating flexibility. It is a form
dependent on the performance characteristics
of reduced-voltage starter that utilizes silicon
of a given configuration of engine and alternator.
controlled rectifiers (SCRs) to increase voltage
These factors are taken into consideration
at a predetermined rate. Limits on the starting
when running the sizing software based on a
current can also be adjusted to increase system
maximum allowable voltage and frequency dip.
performance. A note of caution: any performance
prediction made at a specific value will change Voltage regulator and excitation system
when the settings are changed in the field. Also, response time – Thorough testing has revealed
since solid-state starters utilize nonlinear SCRs, that in addition to the transient reactance of the
they can cause voltage distortion during motor
starting that must be considered. 600
LINE CURRENT - % OF FULL LOAD
100
Full Load Current
Part-Winding Starting
0
100
MOTOR SPEED Full Load
Speed
wye or delta configurations. By connecting the On voltage dips of 35 percent or less, a fast-
motor winding in the wye configuration and using responding system will start the motor faster.
a voltage source corresponding to the delta
rating, starting current and torque are reduced to
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V2 +%
100
-%
Regardless of what sizing method is used or
V3 how manufacturers specify motor-starting
95
performance, the following fundamental criteria
V1 for motor starting must be accomplished – and
90
in the following sequence – to successfully
85 start a motor:
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40.0%
ensure performance of the entire system in
35.0% The entire red shaded area is not
30.0% available if the motor starting
contacts drop out at a 35% voltage
its specific application.
25.0% dip. At a 20% voltage dip
requirement, the area of available
20.0% LRKVA is further reduced.
15.0% QuickSize™ is Kohler’s genset-sizing software;
10.0% it includes industry-leading features, such as
5.0% Nameplate
LRKVA
the ability to select gensets based on voltage
0.0%
0 500 1000 1500 2000 2500 3000 3500
dip, frequency dip and total harmonic distortion.
Motor Nameplate LRKVA These features allow the user to select the genset
set that best fits his or her power requirements.
Figure 10: Motor Nameplate LRKVA vs Voltage Dip The user can select different types of linear and
Source: Kohler Power Systems
nonlinear loads, including motors, VFDs, UPS
systems, battery chargers, office equipment, air
Caution - Maximum LRKVA based on sustained conditioning, miscellaneous loads, lighting and
medical-imaging equipment.
voltage of 90 percent can and usually does
show a much larger value, but the voltage dip QuickSpec™ is an industry-leading system
is typically greater than 35 percent. The LRKVA specification writing tool from Kohler that can
value at 90 percent sustained voltage can be output a complete power system specification
excessively overstated, as it is of no use once for gensets and transfer switches. QuickSpec
outputs the specification into a rich text file that
exceeding either 35 percent instantaneous can be saved in Microsoft Word for easy editing
voltage dip or less, if required by the motor. and customization, allowing the user to integrate
the power system specification into a complete
building specification. To request access to the
QuickSize and QuickSpec programs, contact the
Kohler Power Systems distributor nearest you.
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