POWER SYSTEMS TOPICS 103

SIZING GENERATORS FOR MOTOR STARTING

A Practical Guide to Understanding how Motor-Starting Loads
Affect Generator Performance

AUTHORS INTRODUCTION
DAN KRUEGER
Director of Sales, South Region
Today’s standby power loads are more complex than ever before. In many
RICK VAN MAAREN industrial and commercial applications, standby generator must supply
Senior Staff Engineer
power to a mixture of linear and nonlinear loads in addition to large motor
KOHLER Power Systems loads that cycle on and off. Of all the diverse loads a standby generator must
supply, applications with motors present the most sizing issues. The dynamic
interactions of motors and generators–along with the impact of motor
starters, system inertia, motor loading, frequency dip, generator preload and
nonlinear loading–make manual generator sizing difficult, if not impossible.

Not only is sizing an application with large motors complex, but different
generator manufacturers have different approaches for specifying a standby
power system that will function reliably. Each major generator manufacturer
has created generator-sizing software to help with this complex task, but
due to manufacturers’ differing approaches to motor starting, this software
can yield quite different results—sometimes specifying a larger and more
expensive generator or too small a generator than is necessary for reliable
operation. The purpose of this article is to explain how motors affect
generator performance and how sizing software, such as Kohler Power
Solutions Center, deals with motor loads. Armed with
this understanding, power system specifiers will be able to select the most
cost-effective and reliable generator for motor-starting applications.
 BASIC CHARACTERISTICS OF MOTOR LOADS The motor-starting kVA can be determined by
the motor’s nameplate. The National Electrical
Motor loads cause difficulty because a motor
Manufacturers Association (NEMA) sets design
draws high current when started at full voltage.
standards for motors and has established a
Starting current is typically six times a motor’s
NEMA code-letter designation for classifying
rated full-load current, and this inrush current
motors according to the ratio of locked-rotor
stays high until the motor reaches about 75
kVAs (LRKVAs) per horsepower. These code
percent of rated speed. When a motor is started
letters range from A to V, covering motors with an
on normal utility power, the high inrush current will
LRKVA-per-horsepower ratio of 3.14 or less to a
cause only a small voltage dip because the utility
ratio of 22.4 LRKVA-per-horsepower or more.
is a more robust voltage source. However, when
See Figure 1.
a motor is started on generator power, the high
inrush currents (measured in kilovolt-amperes or For example, a 50 hp Code F motor requires 279.5
KVAs) can result in a large voltage dip LRKVA per horsepower upon starting
that can inhibit the motor from reaching its (50 hp x 5.59 LRKVA per hp = 279.5 LRKVA/hp).
operating speed. LRKVA is also known as “starting kVA” or “SKVA.”
Small motors have a higher NEMA code letter and
The challenge, then, is to size the generator
correspondingly higher LRKVA-per-horsepower
to handle the motor-starting load, but also to
requirement than large motors. Typical motor sizes
minimize the impact on the other connected loads
and codes are shown in Figure 2.
that may be affected by voltage dips or frequency
dips. Therefore, when sizing a generator, it is
critical to accurately predict voltage dips and to VOLTAGE DIP
understand how much excess starting capability
is available in the motor and what amount of The kVA requirements of a motor running at full
voltage dip can be allowed. The most common load and rated speed are normally less than one
methodology for sizing generators for motor kVA per horsepower. With the possible exception
starting focuses on understanding allowable of small motors, it would be overly conservative
instantaneous voltage dips, as the primary criteria. to size a generator set simply by matching the
However, there is one manufacturer that considers alternator’s kVA to the motor’s kVA. This would
allowable sustained voltage dips as the primary typically result in a generator with more than
criteria for motor-starting load. twice the capacity necessary. However, due to the
dynamic interaction of the system components,
kVA per Horsepower several characteristics combine to make this
Letter Designation
with Locked Rotor
approach impractical.
A 0–3.14
B 3.15–3.54 The first characteristic is power factor. Three-
C 3.55–3.99 phase generator sets are usually rated in kVA at
D 4.0–4.49 0.8 power factor. Starting power factors of motors
E 4.5–4.99 vary from 0.3 to 0.5 and increase towards unity as
F 5.0–5.59 the motor accelerates and its kVA demand drops.
G 5.6–6.29 With a 0.4 power-factor load, a typical generator is
H 6.3–7.00 capable of producing nearly twice its continuous-
J 7.1–7.99 rated kVA for the time required to accelerate a
K 8.0–8.99 motor to the speed at which its kVA requirement
L 9.0–9.99 drops sharply. The generator engine will not stall
M 10.0–11.10 even though it is being asked to supply more than
N 11.2–12.49 its rated kVA, because low power-factor loads
P 12.5–13.99 (see Figure 3) do not require as much horsepower
R 14.0–15.99 as higher power-factor loads. This generator
S 16.0–17.99 characteristic allows satisfactory motor-starting
T 18.0–19.99 results with a generator half the size predicted by
U 20.0–22.39 the conservative approach, which matches the
V 22.4 and up generator 0.8 power-factor kVA rating to the
Figure 1: Locked Rotor Indicating Code Letters motor-LRKVA rating.
Source: 2006 NEMA

2 / Sizing Gensets for Motor Starting

 POWER SYSTEMS TOPICS 103

VOLTAGE DIP determining what voltage dip will be acceptable

for a particular load when considering its effect
The other characteristic that can substantially
on all components in the system, some of
reduce the size of the generator needed for a
which may have unknown transient acceptance
particular motor-starting load is voltage dip.
specifications. A voltage dip can affect motors
Values for motor LRKVA are based on full-voltage
themselves, in addition to other loads on the
starting. In practice, there is always a voltage
system. For example, excessive voltage dip can
dip when a motor is started on generator power,
cause control relays or magnetically held motor-
and there is even a small dip when a motor is
starting contactors to drop out, or ultimately
started on utility power. When the voltage drops,
cause the motor to not start at all. If the relays
inrush current is also proportionally reduced so
or contactors drop out, the load is removed
that starting kVA is reduced as the square of the
from the generator, causing voltage to rise and
voltage dip. A 30 percent voltage dip reduces
the cycle to repeat rapidly. This can damage
starting kVA by about 50 percent (0.7 kilovolts x
contactors if allowed to continue. Most control
0.7 amps = 0.49 kVA).
relays and motor-starting contactors will tolerate
Locked Rotor a 35 percent voltage dip. However, there are
Size Code exceptions. Some relays or contactors will start to
KVA/HP
1–2 HP L or M 9–11 chatter if subjected to a voltage dip as little as 20
3 HP K 8–9
percent. Likewise, other voltage-sensitive loads
need to be accounted for (e.g., UPS systems,
5 HP J 7–8
medical equipment, HID lighting) in any generator-
7.5–10 HP H 6–7 sizing exercise. To ensure satisfactory operation
15 HP and up G 5.6–6.3 on a given standby power system, consult
Figure 2: Typical Code Letters for Various HP Motors the voltage/frequency limitations of control
Source: 2006 NEMA
components from the manufacturers or suppliers.
At least for the first few cycles, the voltage Voltage dips also reduce the torque a motor can
dip is determined by the size of the load supply to its load. A common NEMA Design B
(i.e., the motor’s LRKVA) and the reactance of motor will develop 150 percent of rated full-load
the alternator–which is somewhat proportional torque during starting. Torque is proportional to
to the total mass of copper and iron present in the kVA delivered to the motor, so a 30 percent
the alternator. The issue in sizing a generator is voltage dip that reduces kVA to 49 percent also
reduces torque to 49 percent of its rating. If the
motor starts unloaded–as most fans, centrifugal
pumps and motors used with elevators do–this
torque reduction produces no problem other
than a somewhat longer acceleration time. Other
types of loads, such as positive displacement
pumps, may require more torque than the
PF
0.
8 motor can develop at reduced voltage, which
AT prevents the motor from reaching full speed.
A
KV Additional consequences could include tripping
HP P/
E
H of breakers or overheating of the motor. To ensure
F
IN .4 P proper motor starting in these applications, it is
N
G
AT0
E A necessary to compare the torque curves of the
/KV
E HP
GIN pump and the motor at reduced voltage.
EN

AMPS OR KVA
0.4 Power Factor = 50% HP Factor
Figure 3. Engine Power Required
Figure 3: Engine
forPower Required
Low Power for Load
Factor
Low Power-Factor Load
Source: Kohler Power Systems

Sizing Gensets for Motor Starting / 3

 MOTOR STARTERS CAN REDUCE VOLTAGE DIP
600

LINE CURRENT - % OF FULL LOAD

Full Voltage Starting
The high inrush current and high starting torque
associated with full-voltage starting of motors
on utility power may create problems with the
equipment driven by the motor, or the voltage
dips may raise objections from the electric utility. Autotransformer Starting on 65% Tap
To circumvent these issues, many facilities use
various types of motor starters for their motors.
Some of these devices also benefit motor starting 100
Full Load Current
when running on generator power, often allowing 0
a smaller generator to be utilized. MOTOR SPEED Full Load
Speed
Reduced-voltage starters – Most reduced- Figure 5: Autotransformer Starting
Source: Kohler Power Systems
voltage starters connect the load to the power respectively. To avoid reducing starting torque
source in two or more steps. The starters may be to unacceptable levels, use either the 80 or 65
either “open”- or “closed”-transition starters, but percent taps.
only closed-transition, reduced-voltage starters
are helpful when running on generator power. As Solid-state (soft-start) starters – This type of
seen in (Figure 4), open-transition starters create starter is most popular and provides exceptional
an unacceptable spike in kVA demand when operating flexibility. It is a form of reduced-voltage
switching between steps occurs. starter that utilizes silicon controlled rectifiers
(SCRs) to increase voltage at a predetermined
Part-winding starters – Part-winding starters are rate. Limits on the starting current can also be
used with motors that have two identical windings adjusted to increase system performance. A note
intended to be connected in parallel. These of caution: Any performance prediction made at
windings can be energized in sequence to provide a specific value will change when the settings
reduced starting current and torque. Since part- are changed in the field. Also, since solid-state
winding starters are inherently closed-transition starters utilize nonlinear SCRs, they can cause
starters, the maximum inrush current occurs at voltage distortion during motor starting that must
the moment the first winding is energized, and the be considered.
maximum inrush kVA load on a generator set will
be reduced to 60–70 percent of normal. Wye-delta starters – Some motors have six leads
that allow them to be connected in either wye or
Autotransformer starters – This type of starter delta configurations. By connecting the motor
provides reduced voltage at the motor terminals winding in the wye configuration and using a
from a tapped 3-phase autotransformer and voltage source corresponding to the delta rating,
generally gives the best results with generators. starting current and torque are reduced to 33
See Figure 5. Taps on the transformer provide percent of the delta connected values. Use only
selection of 80, 65 or 50 percent of initial line with closed-transition starters, however.
voltage to the motor terminals. Starting torque is See Figure 6.
reduced by the voltage squared to give 64, 42 or
25 percent of the full-voltage value,
Closed Transition Open Transition
6 6

4 4
Line Circuit

Line Circuit

Start
Start

2 2

Run Run
Time Time

Figure 4: Closed Transition vs. Open Transition Starters

Figure 4. Closed Transition vs. Open Transition Starters
Source: Kohler Power Systems

4 / Sizing Gensets for Motor Starting

 POWER SYSTEMS TOPICS 103

Nonlinear loads – Electronic motor starters and

600
LINE CURRENT - % OF FULL LOAD

Full Voltage Starting Variable Frequency Drives (VFDs) are nonlinear

loads. VFDs are not actually a motor-starting
problem but a potential harmonic distortion
problem. Check the generator manufacturer’s
sizing program to see if it predicts the voltage
Wye-Delta Starting
Closed Transition harmonics present when running nonlinear
loads. This can be very useful for analyzing
100 harmonic concerns.
Full Load Current
0 MOTOR LOADING
MOTOR SPEED Full Load
Speed
There are two types of motor loading: high-
FigureStarting
Figure 6: Wye-Delta 7. Wye-Delta Starting breakaway-torque loads (i.e., unloaded motors)
Source: Kohler Power Systems
and high-inertia loads (i.e., loaded motors).
FACTORS AFFECTING REAL-WORLD Unloaded motors – These tend to reach
MOTOR STARTING operating speed quickly. A few examples of
unloaded motors include the following: centrifugal
Generator frequency dip – The generator’s
blowers, rotary and centrifugal pumps (starting
engine cannot be ignored in motor starting due
under low head pressure), clutched motors and
to the high horsepower demanded when a large
fan motors (starting with low restriction). To avoid
motor is started. When the engine slows under
improper operation of magnetic motor starters
load, frequency dips; this, in turn, increases the
and other equipment running on the generator,
alternator voltage dip. The amount of impact on
never exceed a 35 percent instantaneous
engine rpm during motor starting is dependent
voltage dip.
on the performance characteristics of a given
configuration of engine and alternator. These Loaded motors – These tend to take longer to
factors are taken into consideration when accelerate and recover to full voltage, due to the
running the sizing software based on a maximum initial loaded condition of the motor. With loaded
allowable voltage and frequency dip. motors, there is a more significant relationship
between recovery voltage during motor starting
Voltage regulator and excitation system and the generator’s ability to accelerate the
response time – Thorough testing has revealed motor to full speed and rated voltage. A few
that in addition to the transient reactance of the examples of loaded motors include the following:
alternator, voltage regulators and exciters affect rock crushers, elevators, conveyors, single/
voltage dip and recovery. A fast-responding multicylinder compressors and submersible pumps.
excitation system can limit the initial voltage dip
as shown in Figure 7. 120%
110%
On voltage dips of 35 percent or less, a fast-
100%
responding system will start the motor faster.
90%

Preloaded genset – The preexisting load on the 80%

generator can affect both the frequency dip and 70%

voltage dip during motor starting. For example, 60% Fast Responding
Exciter
a 50 percent preloaded generator may dip an 50% Conventional Exciter
additional 2 percent compared to the 40%

published figure. 30%

20%
10%
0%
0 0.5 1 1.5
Time

Figure 7: Motor-Starting Voltage vs. Time

Source: Kohler Power Systems

Sizing Gensets for Motor Starting / 5

 VOLTAGE RECOVERY VERSUS VOLTAGE DIP 2. Sufficient generator torque and power –
Next, the torque available from the generator must
Generator manufacturers differ on some of the
exceed the torque required by the motor load, or
fundamental criteria for proper generator sizing
the motor will stall or never start.
for motor starting. Most manufacturers focus on
instantaneous voltage dip as the primary factor in 3. Sufficient alternator excitation system
generator sizing, while at least one manufacturer strength – The generator must have sufficient
stresses voltage recovery during motor starting excitation system strength and adequate
as the primary driver for generator sizing, which response to accelerate the motor and return it to
can lead to confusing specifications. However, operational voltage and speed. This third and final
extensive field experience indicates that voltage step addresses voltage recovery.
recovery is more a function of exciter size than of
main alternator size, and not a true representation
of the generator’s ability to start the motor. INSTANTANEOUS VERSUS SUSTAINED
While it is necessary to account for the extended
VOLTAGE DIP
acceleration time of motors starting under While most generator manufacturers focus on
a loaded condition, addressing the required instantaneous voltage dip as a primary criterion
LRKVA at the maximum instantaneous voltage for generator sizing, at least one generator
dip experienced by all the connected loads manufacturer writes specifications with a different
should remain the primary criteria. In lab testing maximum motor-starting kVA value that allows
with actual motors and very high inertia loads, the generator voltage to recover to 90 percent of
researchers have found that because of the rated voltage. This concept–known as “sustained
dynamics of motor inrush current and power voltage dip” maximum KVA–assumes that when
factor changes, actual motor-starting capability the generator can recover to 90 percent of rated
is more closely correlated with instantaneous voltage, the motor will develop 81 percent rated
voltage dip than with voltage recovery. Both torque, allowing the motor to accelerate to full
NEMA and MIL standards have recognized that speed in most applications. Real-world experience
the initial voltage dip is the primary criteria to be reveals that using a 90 percent sustained-voltage
used in generator sizing. motor-starting kVA value can overstate motor-
starting performance and lead to improper sizing
of the generator due to dynamic conditions during
FUNDAMENTAL CRITERIA FOR motor starting. See Figure 8.
MOTOR STARTING
Regardless of what sizing method is used or 105
V4
how manufacturers specify motor-starting
VOLTAGE (PERCENT OF RATED)

V2 +%
100
performance, the following fundamental criteria -%

V3
for motor starting must be accomplished–and 95

in the following sequence–to successfully V1

90
start a motor:
1. Sufficient LRKVA at the instantaneous 85

voltage dip for inrush current – The required 80

T0 T1 T2

LRKVA at the maximum permissible instantaneous TIME (SECONDS)

voltage dip is considered to be the first step for V1 = Voltage dip T0 = Point at which load is applied
V2 = Maximum transient voltage overshoot T1 = Time to recover to a specified band
motor starting by most generator and alternator V3 = Recovery voltage T2 = Time to recover to and remain

manufacturers. Typical motors are designed to V4 = Steady-state regulator within the specified band

sustain a 30 to 35 percent instantaneous voltage Figure 8: Generator Transient Voltage vs.Time

dip before the motor-starting contacts drop out. for Sudden Load Change
Many specifying engineers prefer a maximum 20 Source: 2006 NEMA MG1 Part 32

percent instantaneous voltage dip limit to ensure

the motor will start and hold in the starting contacts.

6 / Sizing Gensets for Motor Starting

 POWER SYSTEMS TOPICS 103

See Figure 9 CONCLUSION

Caution – Maximum LRKVA based on sustained When using a generator to supply motor-starting
voltage of 90 percent can and usually does loads, the interactions are dynamic and complex.
show a much larger value, but the voltage dip For the most reliable and accurate results, the
is typically greater than 35 percent. The LRKVA sizing exercise needs to consider the generator as
value at 90 percent sustained voltage can be a system, including the engine, alternator, voltage
excessively overstated, as it is of no use once regulator and excitation system, along with motor
exceeding either 35 percent instantaneous starters. Dynamic conditions, such as systems
voltage dip or less, if required by the motor. inertia, motor loading, motor type and generator
preload, are also important. By analyzing this
Motor Nameplate LRKVA vs Voltage dip dynamic system and evaluating the functions
in real-world applications, specifiers will have a
60.0%
Instantaneous Voltage Dip Rating better understanding of how to properly predict
55.0% at 90% Sustained Voltage Dip
50.0% motor-starting performance in a more consistent
45.0% and reliable way.
Voltage Dip (%)

40.0%
Finally, due to the complexity of total system
35.0% The entire red shaded area is not
30.0% available if the motor starting loads and the dynamics of the generator and
contacts drop out at a 35% voltage
25.0% dip. At a 20% voltage dip motor-starting applications, it’s important to
requirement, the area of available
20.0% LRKVA is further reduced. utilize proven generator-sizing software to
15.0% ensure performance of the entire system in its
10.0% specific application.
Nameplate
5.0% LRKVA
0.0%
0 500 1000 1500 2000 2500 3000 3500
Motor Nameplate LRKVA

Figure 9: Motor Nameplate LRKVA vs. Voltage Dip

Source: Kohler Power Systems

Power Solutions Center is Kohler’s intuitive

generator sizing and specifying software.
It includes industry-leading features such
as the ability to select generators based
on voltage dip, frequency dip and total
harmonic distortion. These features allow
the user to select the generator set that
best fits his or her power requirements. The
user can select different types of linear and
nonlinear loads including motors, VFDs, UPS
systems, battery chargers, office equipment,
air conditioning, lighting, medical-imaging
equipment, and more. For access to the
Power Solutions Center, go to kohlerpower.
com/industrial.

Sizing Gensets for Motor Starting / 7

 POWER SYSTEMS TOPICS 103

ABOUT THE AUTHORS

Dan Krueger is the Director of Sales for the Southern region for Kohler
Power Systems. He has worked within the power generation industry for
more than 20 years in manufacturing, product and business management,
and sales both domestically and internationally. Krueger joined Kohler
in 1998, primarily working with the engineering community, supporting
system sales and providing training on KOHLER ® products and paralleling
switchgear systems.

Rick Van Maaren is a Senior Staff Engineer with Kohler Power Systems.
He has worked in alternator development of standby, marine, residential
and mobile generators for more than 30 years. He holds a bachelor's
degree in electrical engineering from Michigan Technological University, is a
registered professional engineer in the state of Wisconsin, a senior member
of the Institute of Electrical and Electronics Engineers (IEEE) and a holder
of seven patents. He has authored an IEEE Industry Applications Society
(IAS) paper titled Rotor Lamination Design for Surface Permanent Retention at
High Speeds and a chapter of the Electrical Generating Systems Association
(EGSA) On-Site Power Generation reference book
titled "Permanent Magnet Generators".

A global force in power solutions since 1920, Kohler is committed to reliable,

intelligent products; purposeful engineering and responsive after-sale
support. Kohler’s acquisition of SDMO in 2005 created one of the world’s
largest manufacturers of industrial generators. The companies have a
combined 150 years experience in industrial power and now benefit from
global R&D, manufacturing, sales, service and distribution integration.

KOHLERPOWER.COM
Printed in U.S.A. G26-7 KPS 103 1/18 © 2018 by Kohler Co.