Abstract:
The present invention is a method and system for monitoring the continuous flow of power delivered by multiple DC Direct current operated starter motors used to start engine driven electrical generators. The method and system comprise the closing of a starter battery system and an associated starter control switch, causing the starter battery system to discharge through a shunt whereby current is fed into a starter motor. The shunt is optionally provided as a precision resistor with a pre-calibrated voltage drop in millivolts DC proportional to a current passing through it. The shunt directs current to a meter relay, which is calibrated by establishing two set points, or desired trigger ranges, for the meter relay. If the current falls outside a range established by the two set points, then a meter relay alarm output is activated; and, if the current remains within the range, then the meter relay alarm output is not activated. The meter relay alarm output is, optionally, a dry contact which activates a signal device.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority from U.S. Provisional Patent Application Ser. No. 61/173,415, filed Apr. 28, 2009, the entire contents of which is herein incorporated fully by reference. 
     
    
     FIGURE FOR PUBLICATION 
       [0002]    To be selected. 
       BACKGROUND OF THE INVENTION 
       [0003]    1. Field of the Invention 
         [0004]    The present invention relates to a system for monitoring and testing the secure operation of power generators and related power supply systems. More specifically, the present invention relates to a system for ensuring the continuous flow of power delivered to multiple direct current (DC) operated starter motors where these are used to start a prime mover of an electrical generator such as a reciprocating engine or a turbine engine and to minimize starter motor failure or non-scheduled down-time. 
         [0005]    2. Description of the Related Art 
         [0006]    Industry and commerce has been, and continues to be, powered by a growing supply of large engine-driven electrical generators which are primarily used to drive (supply power to) large data centers and industrial and medical complexes, among other applications. These large scale generators are typically supplied with two electric starter motors to start the associated engine. These motors are typically 24 volt DC and each have a separate battery source. 
         [0007]    In a very large-tier data center (for example—a Tier 3 or Tier 4 data center), with turn-key costs of approximately one hundred million dollars ($100,000,000), with standby power being as much as 25% of the investment, the back-up power generators are massive and must have a very low failure rate. These engines often operate at approximately 4000 HP, driving 3.5 Megawatt, 1800 RPM electrical generator rated at 5 or 15 KVAC. Conventionally, each of these large power sources is started with two starter motors in parallel (each producing its share of starting torque and HP to crank the engine in a shared mode at the same time). Effective starting of the starter motors is crucial, as it results in ultimate operation of the back-up power generator. Failure of the starter motors has a cascading affect on the system, thus causing failure. Unfortunately, in current systems, the parallel installation of the starter motors does not provide notice if the first starter motor fails to operate. If the first motor does fail to operate, then the second starter motor will bear the strain of a dual load, leading to its unpredictable and eventual failure at an accelerated pace. 
         [0008]    In normal operation, the starting power of the system is on the order of 1000-1300 Amps which is split between the two starter motors. If the first motor fails, then the second motor draws the entire amperage load. Currently available monitoring systems do not exist, or are not adequate in their profile building, so there is little or no means of predicting failure in the second starter motor. 
         [0009]    As a result of system failure involving second starter motors, it is often determined in post-operative analysis that both motors had failed: the first through various defects or anomalies; and, the second through overload of the starter relays, or through failure of a starter solenoid, winding failures, bearing failures or several other failure modes. Many of these failure modes are accelerated by severe stress from having to bear the full amperage load together with a failure in preventative or predictive maintenance. 
         [0010]    What is not appreciated by the prior art is that there is a need in the market to address the issue of back-up starter motor failure and to incorporate the same into a preventive maintenance cycle so as to protect the high-draw devices and systems being driven by electrical input. 
         [0011]    Accordingly, there is a need for an improved method, system, and apparatus for monitoring and testing multiple DC electrically operated starter motors to start an engine. 
         [0012]    Additionally, there is needed a method and system that will give a warning to a system operator of a failure of either starter motor in a power generating system. 
       ASPECTS AND SUMMARY OF THE INVENTION 
       [0013]    An aspect of the present invention is to provide a method and system for monitoring and testing multiple electrically operated starter motors which are used to start an engine driven electric power generator 
         [0014]    Another aspect of the present invention is to provide a method and system that will give a warning to a system operator of a failure of either starter motor in a power generating system and the ability to effectively predict the same. 
         [0015]    The present invention relates to a method and system for monitoring the continuous flow of power delivered by multiple starter motors used to start and engine driven electric generator. The method and system comprise the closing of a starter battery system and an associated starter control switch, causing the starter battery system to discharge through a shunt whereby current is fed into a starter motor. The shunt is a precision resistor with a pre-calibrated voltage drop in millivolts DC proportional to a current passing through it. The shunt directs current to a meter relay, which is calibrated by establishing two set points for the meter relay. If the current falls outside a range established by the two set points, then a meter relay alarm output is activated; and, if the current remains within the range, then the meter relay alarm output is not activated. The meter relay alarm output is a dry contact which activates a signal device together with a visual indication at the meter. 
         [0016]    According to an embodiment of the present invention there is provided a method and system for monitoring the continuous flow of power delivered by multiple DC starter motors on the engine driven electric generator. An initial step of the method and system comprises the closing of a starter battery system and an associated starter control switch, causing the starter battery system to discharge through a shunt whereby current is fed into a starter motor. Subsequent steps comprise calibrating a meter relay, then establishing two set points for the meter relay. If the current falls outside a range established by the two set points (on either side of the established range), then a meter relay alarm output is activated; and, if the current remains within the range, then the meter relay alarm output is not activated. 
         [0017]    The shunt is (not restricted thereto, optionally, a Hall Effect device) a precision resistor with a pre-calibrated voltage drop in millivolts DC proportional to a current passing through it; and, is rated up to, and including for example, 2000 amperes DC at 100 millivolts. If 1000 amperes DC were passing through the shunt, the shunt would cause a voltage drop across the shunt of approximately 50 millivolts. Thus, the voltage drop across the shunt, relative to amperes DC passing through the shunt, establishes a proportion, wherein the proportion is maintained for any amperage at 2000 amperes DC or below. 
         [0018]    The method and system&#39;s meter relay alarm output is both a local meter visual indicator and a dry contact which activates a signal device such is a bell or one or more lights. Additionally, the signal device could be a digital signal in a communication protocol for interfacing with a monitoring system; or, could be an Ethernet connection for transmitting the signal via a wireless communication system. 
         [0019]    According to an alternative embodiment of the present invention, there is provided a method and system for monitoring the continuous flow of power delivered by multiple starter power generators. An initial step of the method and system comprises the closing of a starter battery system and an associated starter control switch, causing the starter battery system to discharge through a shunt whereby current is fed into a starter motor. Subsequent steps comprise directing DC current flow through a Hall Effect Device having a wire cable throughput and inducing a current signal from the wire cable throughput, wherein the current signal can be read by a control and alarm circuit further comprising the meter relay. 
         [0020]    The control and alarm circuit is capable of establishing a hysteresis upon the starting of an engine wherein the circuit will ignore for a period of time (usually in milliseconds) a high current surge as the starter motor beings to turn. The control and alarm circuit will self-calibrate by taking a steady state current, as the starter motor is turning over the engine, and establishing the steady state current as a baseline current; and, then utilizing the set points to establish the range to be applied to the baseline current. 
         [0021]    If the current falls outside the range established by the two set points, then the meter relay alarm output is activated; and, if the current remains within the range, then the meter relay alarm output is not activated. 
         [0022]    The Hall Effect device has a pre-calibrated output signal in proportion to a current passing through it; and, is rated up to, and including, 2000 amperes DC. If 1000 amperes DC were passing through the device, the device would cause the output signal to be proportional to 1000 amperes. Thus, the output signal, relative to amperes DC passing through the device, establishes a proportion, wherein the proportion is maintained for any amperage at 2000 amperes DC or below. 
         [0023]    The method and system&#39;s meter relay alarm output is a dry contact which activates a signal device such is a bell or one or more lights. Additionally, the signal device could be a digital signal in a communication protocol for interfacing with a monitoring system; or, could be an Ethernet connection for transmitting the signal via a wireless communication system. 
         [0024]    In a further embodiment of the present invention, a circuit module can be interoperably connected to the starter motor for applying a test voltage for determining the possibility of the starter motor&#39;s failure due to deterioration of the electrical insulation of the starter motor&#39;s windings. The circuit module further comprises application means for applying a DC test voltage within the range of 50-500 VDC to the starter motor windings. Additionally, the circuit provides measuring means for measuring the ohmic resistance of the starter motor windings to determine a measured value; the measured values are compared with a pre-established profile value of the starter motor to determine a compared value. If the measured value is proximate to the profile value, then failure of the starter motor due to insulation failure is not imminent; however, if the measured value is low relative to the profile value, then the circuit will determine that failure of the starter motor due to the deterioration of the insulation is imminent. 
         [0025]    The above, and other objects, features and advantages of the present invention, will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]      FIG. 1  is a circuit diagram utilizing a conventional shunt and meter relay within the system of the present invention. 
           [0027]      FIG. 2  is a circuit diagram utilizing a Hall Effect Device providing an induced output signal proportional to the DC direct current passing through the monitored cable with a self calibrating current sensing alarm circuit (instead of a meter relay) within the system of the present invention. 
           [0028]      FIG. 3A  is a block diagram of the system of the present invention utilizing a battery as the power source. 
           [0029]      FIG. 3B  is a block diagram of the system of the present invention utilizing a battery and a super capacitor as the power source. 
           [0030]      FIG. 4  is a flowchart of the method of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0031]    Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms, such as top, bottom, up, down, over, above, and below may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner. The words “connect,” “couple,” and similar terms with their inflectional morphemes do not necessarily denote direct and immediate connections, but also include connections through mediate elements or devices. 
         [0032]    Turning then to  FIG. 1 , there is shown a circuit diagram  10  utilizing a conventional shunt and meter relay within the system of the present invention. 
         [0033]    The starting battery system and associated starter switch  15  are allowed to close at point  20 , and the battery to discharge through shunt  25  feeding current into starter motor  30 . 
         [0034]    The shunt  25  is a precision resistor with a pre-calibrated precision voltage drop in millivolts DC proportional to the current passed through it—i.e. for example, the shunt is rated for 2000 amperes DC at 100 millivolts, so at 1000 A passing through the voltage drop across the shunt will be 50 millivolts, at 500 A passing through the shunt it will be 25 millivolts, and so on. It shall be noted that for the purposes of this disclosure the disclosure is not limited to the particular ratings, amperes, voltages etc. which are employed as examples only. Nothing herein shall be seen to limit the proposed system, method, and apparatus to a specific electronic or electrical rating. 
         [0035]    The meter relay  35  (such as can be commercially obtained from Fairchild Semiconductor Corporation of South Portland, Me.) is calibrated wherein full scale is shown as, for example, 2000 amperes DC on the meter when it is reading 100 millivolts from the shunt  25 . The meter relay  35  has two sets points or trigger-type thresholds (one high and one low—not shown) which can be set above and below some nominal normal value of current as will be determined by a desire of system operators and system engineers. If the current read on the meter relay  35  is “normal” or within a range of normal (i.e., for example +/−10% or another percentage determined as ‘normal’), then the meter alarm set points do not operate or trigger. The signal conditioner  32  has a built-in “hysteresis” system so that the meter relay  35  ignores as a valid reading the first few milliseconds (a user-determined/user-desired time value) of high current surge before the starter motor  30  begins to turn—this prevents false alarms at initial start. 
         [0036]    If the current goes above the preset limit/threshold, or below the preset limit/threshold (or any other type of control parameter that may be employed in combination, such as duration (time function) above a preset-limit), the meter relay  35  alarm will actuate giving alarm output  40 . The alarm output  40  can be a dry contact which can be of a conventional operation or other system; for example causing the ringing of a bell, operation of warning lights, trigger to a user&#39;s control panel, a PID-type (proportional-integral-derivative-type) monitor or controller, or it can be digital signal in a communication protocol such as Modbus™ (a serial communications protocol published by Modicon for use with programmable logic controllers (PLCs)) to interface with a building monitor system. It can even be an Ethernet-type or Bluetooth-type connection (via one or more Hubs or over the Internet (as opposed to a cellular based system)) wherein the alarm output  40  can be received and read via wireless internet connection, PDA, cellular device, phone or other electronic monitoring device. It shall be understood that such a signal (notice of an above/or lower than normal set point current) may in turn trigger other actions such as an automatic scheduling of a maintenance action, ordering of a replacement part, sending of an email or facsimile, a call with an auto-recorded message, etc. 
         [0037]    It should be noted, in general, that the sensing of a lower than normal current could indicate that the starter, or its associated starter relay, are malfunctioning, have gone bad in some way, or, that there is some high resistance in the connections which is limiting proper flow of current to the starter which would not allow it to develop the necessary horsepower (HP) and torque to perform its intended function. (NOTE. Consider the formula wherein electrical power in watts equals volts times amperes (P=IV); this can equate directly to HP, as 746 watts equals 1 HP.) 
         [0038]    The sensing of a higher than normal current could indicate a short circuit in the starter motor, or its associated starter relay, that allows current to flow to ground through a low resistance path, while not creating mechanical HP and torque in the starter. The higher than normal current could also be an indication of a short to ground in the cabling or connections from the battery power source to the starter motor and its associated starter relay, which would have a similar debilitating effect on the starter motor performance. 
         [0039]    In addition, and as previously mentioned, excessive high current indications could indicate that a single starter is doing the work of two (or more) starters while its companion(s) has/have ceased to function altogether. The remaining starter pulls an extra-heavy current load to produce enough HP and torque to crank the engine, but it does so in an overloaded condition (internal overheating, reduced insulation life, etc.) which will eventually result in premature failure of the starter motor. 
         [0040]    It will be recognized by those of skill in the related arts that the above-discussion of sensing higher/lower than normal current flows and results may be equally applied to the related embodiment discussed below, and the same should be additionally incorporated following the discussion. 
         [0041]    Turning next to  FIG. 2 , there is shown a circuit diagram  100  utilizing a Hall Effect device  115  instead of a shunt to provide a measurable signal output proportional to the DC direct current flow in the starter motor electrical feeder cable passing through the Hall effect device. This signal is be interpreted by a self calibrating current alarm electronic circuit instead of a meter relay. Such a circuit includes, but is not limited to, a built-in “hysteresis” control system to ignore (or allow without alarm) a high initial inrush current. The system self-establishes to a normal average current when each starter motor is good and functioning normally, or upon operator designated re-set or designation of a new functional norm. The circuit contains alarm thresholds preset in the circuitry at some reasonable percentage above and below the normal current such as +/−10%. As an alternative the circuit may include a programming management function to allow an authorized user to input or change the alarm threshold presets. In this manner, during operation, if the current flow exceeds these limits it would be indicative of a starter motor problem. A high current could indicate the other starter had failed. Or it could indicate this starter motor has an internal short circuit. A low current could indicate this starter had some inordinate high resistance and was not allowed to draw sufficient current to produce its required share of torque and shaft horsepower. In either circumstance, an alarm would be triggered requiring a maintenance and operational assessment. 
         [0042]    The starting battery system and associated starter control switch  110  are allowed to close at point  20 A and the battery to discharge through Hall effect Device  115  feeding current into starter motor  125 . 
         [0043]    The Hall Effect device  115  is a precision electronic device which can have a wire cable put through it. The Hall effect itself is the production of a potential difference across an electrical conductor, positioned transverse to an electric current in the conductor and a magnetic field perpendicular to the current. As discussed herein, the DC current flow into the starter motor  125  through that cable will induce a solid state device to produce a current signal  120  from the Hall Effect device that can be read and interpreted by a control and alarm circuit  130  that puts out an alarm signal  135 . It will be recognized by those of skill in the art, following study of the present disclosure, that similar results, signals, analysis, triggers, etc. to those discussed in relation to embodiment 1 (see  FIG. 1 ), may also be pursued. 
         [0044]    The electronic sensing and alarm circuit, broadly depicted at  135 , can take in the signal from the Hall effect device  115 . On initial starting of the engine (not shown) the electronic sensing and alarm circuit  130  will have a hysteresis so that it ignores the high current surge for the first few milliseconds (or programmably longer or shorter) as starter motor  125  starts to turn. It then can be designed to “self calibrate” (for example during a first-installation use or during a self-calibration cycle) where it monitors and recognizes (takes) the steady state current, as the starter motor  125  is cranking the engine, as the “normal” current and sets that as its reference (allowing a designation of high/low current limits in relation thereto). As currently discussed, but not limited thereto, the electronic sensing and alarm circuit  130  has a preset adjustable set of high and low limits for alarm signals which would nominally be preset (+/−10%) around the “self calibrated” initializing normal level. 
         [0045]    If the current goes above the preset limit, or below the preset limit, the meter relay alarm will actuate giving alarm output  135 . The alarm output  135  can be a dry contact which rings a bell or lights a light on the users control panel or it can be a digital signal in a communication protocol such as Modbus™ to interface with a building monitor system. It can even be an Ethernet connection wherein the alarm output can be read via wireless internet connection, PDA, cellular device, phone or other electronic monitoring device. 
         [0046]    Those of skill in the art, having studied the current disclosure, will recognize that the “self calibrate” cycle or process noted above can be pre-programmed into a computerized memory unit (not shown) in operative connection with circuit  130  so as to store in an electronic memory (RAM/ROM/other) and an operative control system in an initial start up or designated baseline current flow. This unit is not shown, but will be understood to include current sensing alarm  130  and related matters including (optionally) the Hall effect system  115 . The circuit  130  may thereafter include programming allowing designation or acceptance of the baseline current flow as an operative norm (e.g., changing one or more data points in the electronic memory) and may thereafter set or designate upper and lower warning or alarm levels in relation thereto—and similarly save these in the electronic memory by updating the same. 
         [0047]    Turning then to  FIG. 3A , there is shown a block diagram of the system  200  of the present invention utilizing a battery  220  as the power source. The system  200 , defined herein, resides in an enclosure of a type that is available from McMaster-Carr Supply Company of Elmhurst, Ill.). 
         [0048]    In a single starter system, a suitably rated diode  224 , capable of carrying the required cranking current amperage with a minimum voltage drop, is connected in series to the starter  226 . The diode  224  will electrically isolate each starter battery  220  and its associated battery charger. The diode  224  value is such that if one of the batteries  220  develops an internal fault, the other battery  220  will not be drained while trying to start the engine  210 . Use of such diode isolators  224 , generally referred to in the industry as “best battery selectors”, are known for use in dual battery systems. Additionally, diode isolators  224 , with associated heat sinks (such as the power semiconductor heat sinks commercially available from Wakefield Thermal Solutions, Inc. of Pelham, N.H.), can be easily incorporated into the present system  200 . 
         [0049]    The battery  220  voltage is run through voltage meter  228  to measure the voltage across the circuit. In turn, a battery voltage monitor and signal conditioner  234  interfaces with the voltage meter  228  (exemplary meters are commercially available from Newport Electronics, Inc. of Santa Ana, Calif.). 
         [0050]    For the basic system to work, it is necessary to incorporate a current sensing time delay and signal conditioning circuit as an interface between the current sensor (shunt or Hall Effect device) and the starter current meter relay which will detect an over or under current condition. This is needed to buffer the input to the meter relay from high initial starter amperage inrush current which would provide a “false” alarm output. 
         [0051]    This circuit can be combined with a starter  226  battery  220  charging and battery dip voltage “sample and hold” monitoring device. The voltage monitoring of charging voltage, with a digital display and alarm  230  can be used to assure that the battery  220  is getting proper “float” charging voltage applied. This is necessary to assure that the battery  220  will be in a state of full charge when called upon. 
         [0052]    The second voltage monitor circuit looks at the voltage low point to which the battery  220  dips when the engine  210  is cranked. There are industry accepted criteria (e.g., SAE, EGSA) that have established at what level this voltage dip point indicates an “unhealthy battery.” This added circuit will alarm under an excessive sensed DC voltage dip on a given cranking engine  210  start cycle. It can be pre-set to alarm at a threshold which is still high enough to allow adequate starting but indicate battery is becoming marginal. So it can function for facilities people as a “feed forward” predictive maintenance diagnostic tool. Before they have a problem, they can check the batteries, which in the case of normal lead acid truck batteries used in many of these applications, are prone to “sudden death” failure modes. 
         [0053]    The battery voltage monitor and signal conditioner  234  outputs a voltage alarm  230  in the event that the circuit voltage drops outside acceptable parameters, and outputs a voltage failure alarm  232  in the event that voltage fails. 
         [0054]    The battery voltage monitor and signal conditioner  234  interfaces with a current sensor  222  which in turn is in the current stream coming off the battery  220 . The current sensor  222  allows the current to continue to the isolation diode  224  before the current is utilized by the starter  226 . 
         [0055]    Further, in a reciprocal relationship with the battery voltage monitor and signal conditioner  234  is a current process meter  236 . The current process meter  236  evaluates the current passing therethrough and activates a high current alarm output  238  if the current is above the applicable set point, or activates a low current alarm output  240  if the current is below the applicable set point. 
         [0056]    In a further embodiment of the present invention, a circuit module (not shown) can be interoperably connected to the starter motor  226  for applying a test voltage for determining the possibility of the starter motor  226  failure due to deterioration of the electrical insulation of the starter motor  226  windings. Such circuits are commercially known; a representative module embodying such a circuit is commercially available from Automeg, Inc. of Astatula, Fla. and is available as a 12 pin plug-in module in various configurations. The circuit diagram and module design are disclosed on the Automeg website (www.automeg.com) and are incorporated herein in their entirety. 
         [0057]    The circuit module further comprises application means for applying a DC test voltage within the range of 50-500 VDC to the starter motor windings. Typically, a new motor will meet very high resistance of the windings to ground (generally in the range of 100 meg ohms). If the measured ohmic resistance is down in the range of 1 meg ohm, or less, then the motor may be on the verge of failure. Additionally, the circuit provides measuring means for measuring the ohmic resistance of the starter motor  226  windings to determine a measured value; the measured values are compared with a pre-established profile value of the starter motor to determine a compared value. If the measured value is proximate to the profile value, then failure of the starter motor due to insulation failure is not imminent; however, if the measured value is low relative to the profile value, then the circuit will determine that failure of the starter motor  226 , due to the deterioration of the insulation, is imminent. 
         [0058]      FIG. 3B  shows an alternative embodiment of the present invention in a block diagram of the system  260  utilizing a battery  268  and a capacitor  270  as the power source. The system  260 , defined herein, resides in an enclosure of a type that is available from McMaster-Carr Supply Company of Elmhurst, Ill.). The method and system described herein can be applied to a dual starter system (contemplated hereby) as well, by doubling up the components required and identified herein. 
         [0059]    The capacitor  270  can be of a type as disclosed in U.S. Pat. Nos. 5,986,876 for a Double Layer Capacitor, issued to Stepanov et al.; 6,181,546 for Double Layer Capacitor, issued to Stepanov et al.; and, 6,222,723 for an Assymmetric Electrochemical Capacitor And Method Of Making, issued to Razoumov et al. The entire contents of each of which is incorporated herein by reference. 
         [0060]    In a single starter system, a suitably rated diode  274 , capable of carrying the required cranking current amperage with a minimum voltage drop, is connected in series to the starter  276 . The diode  274  will electrically isolate the starter battery  268  and super capacitor  270 . The diode  274  value is such that if the battery  268  and super capacitor  270  develop an internal fault, a redundant battery  268  and super capacitor  270  will not be drained while trying to start the engine  265 . Additionally, diode isolators  274 , with associated heat sinks (such as the power semiconductor heat sinks available from Wakefield Thermal Solutions, Inc. of Pelham, N.H.), can be easily incorporated into the present system  260 . 
         [0061]    The voltage coming off the battery  268  and capacitor  270  is run through voltage meter  278  to measure the voltage across the circuit. In turn, a battery voltage monitor and signal conditioner  284  interfaces with the voltage meter  278  (exemplary meters are commercially available from Newport Electronics, Inc. of Santa Ana, Calif.). 
         [0062]    For the basic system to work, it is necessary to incorporate a current sensing time delay and signal conditioning circuit as an interface between the current sensor (shunt or Hall Effect device) and the starter current meter relay which will detect an over or under current condition. This is needed to buffer the input to the meter relay from high initial starter amperage inrush current which would provide a “false” alarm output. 
         [0063]    This circuit can be combined with a battery  268  and capacitor  270  voltage “sample and hold” monitoring device. The voltage monitoring of charging voltage, with a digital display and alarm  280  can be used to assure that the battery  268  and capacitor  270  is getting proper “float” charging voltage applied. This is necessary to assure that the battery  268  and capacitor  270  will be in a state of full charge when called upon and that the battery  268  is in good condition. 
         [0064]    The second voltage monitor circuit looks at the voltage low point to which the battery  268  and capacitor  270  dips when the engine  265  is cranked. There are industry accepted criteria (e.g., SAE, EGSA) that have established at what level this voltage dip point indicates an “unhealthy” battery, or capacitor, or both. This added circuit will alarm under an excessive sensed DC voltage dip on a given cranking engine  265  start cycle. 
         [0065]    The battery voltage monitor and signal conditioner  284  outputs a voltage alarm  280  in the event that the circuit voltage drops outside acceptable parameters, and outputs a voltage failure alarm  282  in the event that voltage fails. 
         [0066]    The battery voltage monitor and signal conditioner  284  interfaces with a current sensor  272  which in turn is in the current stream coming off the battery  268  and capacitor  270 . The current sensor  272  allows the current to continue to the isolation diode  274  before the current is utilized by the starter  276 . 
         [0067]    As with  FIG. 3A  hereinabove, in a further embodiment of the present invention, a circuit module (not shown) can be interoperably connected to the starter motor  276  for applying a test voltage for determining the possibility of the starter motor  276  failure due to deterioration of the electrical insulation of the starter motor  276  windings. Such circuits are commercially known; a representative module embodying such a circuit is commercially available from Automeg, Inc. of Astatula, Fla. and is available as a 12 pin plug-in module in various configurations. The circuit diagram and module design are disclosed on the Automeg website (www.automeg.com) and are incorporated herein in their entirety. 
         [0068]    The circuit module further comprises application means for applying a DC test voltage within the range of 50-500 VDC to the starter motor windings. Typically, a new motor will meet very high resistance of the windings to ground (generally in the range of 100 meg ohms). If the measured ohmic resistance is down in the range of 1 meg ohm, or less, then the motor may be on the verge of failure. Additionally, the circuit provides measuring means for measuring the ohmic resistance of the starter motor  276  windings to determine a measured value; the measured values are compared with a pre-established profile value of the starter motor to determine a compared value. If the measured value is proximate to the profile value, then failure of the starter motor due to insulation failure is not imminent; however, if the measured value is low relative to the profile value, then the circuit will determine that failure of the starter motor  276 , due to the deterioration of the insulation, is imminent. 
         [0069]    Further, in a reciprocal relationship with the battery voltage monitor and signal conditioner  284  is a current process meter  286 . The current process meter  286  evaluates the current passing therethrough and activates a high current alarm output  288  if the current is above the applicable set point, or activates a low current alarm output  290  if the current is below the applicable set point 
         [0070]      FIG. 4  is a flowchart of the method of the present invention. The method begins with the initiation of the starter battery system at step  300 . From step  300 , the method advances to step  302  where the closing of the starter battery switch causes the starter battery system to discharge through a shunt. 
         [0071]    The shunt can be a precision resistor with a pre-calibrated voltage drop in millivolts proportional to a current passing through it. Additionally, the shunt is rated up to, and including, 2000 amperes DC at 100 millivolts. At 1000 amperes DC passing through the shunt, the shunt will cause a voltage drop across the shunt of approximately 50 millivolts. The voltage drop across the shunt relative to the amperes DC passing through it establishes a proportion, wherein the proportion is maintained by any amperage at 2000 amperes DC or below. 
         [0072]    Discharge through the shunt (such as those commercially available from PC&amp;S of Stanhope, N.J.) causes the method to advance to step  304  where the current is then fed to the starter motor. 
         [0073]    A meter relay is calibrated at step  306  and two set points are established at step  308  for the meter relay. The current going to the starter motor is monitored at step  310 . From step  310 , the method flow advances to step  312  where the system queries as to whether or not the current being monitored falls outside the range established by the set points. If the response to the query is “NO”, then the flow advances to step  314  where the meter relay alarm is maintained in the inactive position while the flow continually re-enters the method flow at step  310 . However, if the response to the query at step  312  is “YES”, then the method flow advances to step  316 . 
         [0074]    At step  316 , the meter relay alarm output causes a signal device to activate so as to indicate that the current is not within the established set points. In turn, the alarm/signal activation will cause the starter battery system to shut down at step  318 . The meter relay alarm output is a dry contact which activates the signal device, which can be: a bell; a set of one or more lighting devices; a digital signal in a communication protocol for interfacing with a monitoring system; or, an Ethernet connection for transmitting the signal via a wireless communication system. 
         [0075]    As another alternative embodiment of the present invention it will be recognized that any aspect of the above-noted embodiments may be additionally enhanced when used in combination with additional technological sensing systems (including their own related support systems, electrical connections, etc). For example, it is know that miniaturized infrared (IR) sensors, which can generate a temperature signature signal indicator and can be integrated into a computerized control system (like that proposed for the present invention) such that both a current monitoring and an additional monitoring system (here the IR monitoring system) may be used as parallel monitoring systems. Similarly, it will be recognized by those of skill in the relevant arts that an additional functional parameters may be sensed and monitored. These include, but are not limited to, vibration or harmonic sensing, acoustical sensing, and vibratory sensing. 
         [0076]    In view of the above disclosure, those of skill in the related arts will recognize that the proposed system maybe provided optionally as a portable hand-held sensing, monitoring, or testing unit or as a non-hand-held integrated unit that is fully incorporated into a power supply system in a non-portable way. In any of the optional and adaptive embodiments (portable/non-portable) the same features may be provided, and the systems provided by the FIGs. herein may be pursued without escaping from the scope and spirit of the present invention. 
         [0077]    In the claims, means or step-plus-function clauses are intended to cover the structures described or suggested herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, for example, although a nail, a screw, and a bolt may not be structural equivalents in that a nail relies on friction between a wooden part and a cylindrical surface, a screw&#39;s helical surface positively engages the wooden part, and a bolt&#39;s head and nut compress opposite sides of a wooden part, in the environment of fastening wooden parts, a nail, a screw, and a bolt may be readily understood by those skilled in the art as equivalent structures. 
         [0078]    For purposes of recognizing adaptability of the claims it will be recognized that the shunt noted in the claims may alternatively be understood to operate as the Hall Effect device and associated alarm and monitoring circuit, without departing from the scope and spirit of the present invention. 
         [0079]    Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes, modifications, and adaptations may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.