Testing; Weekly Generator Set Exercise; Monthly Automatic Operation Test; Other Tests - Kohler KEP Service Manual

1.4 Testing

Periodic testing is important in any transfer switch
application. It helps to ensure that the generator set will
start and the transfer switch mechanisms and control
circuits will operate when needed.
1.4.1

Weekly Generator Set Exercise

Use the plant exerciser to start and run the generator set
once a week to maximize the reliability of the emergency
power system. See the transfer switch operation and
installation manual for additional information about the
exerciser.
1.4.2

Monthly Automatic Operation Test

Test the transfer switch's automatic control system
monthly by running a loaded or auto-load test. See
Section 3.6.4 or the transfer switch operation and
installation manual for the test procedure. Verify that the
expected sequence of operations occurs as the switch
transfers the load to the emergency source when a
normal source failure occurs or is simulated. After the
switch transfers the load to the emergency source, end
the test and verify that the expected sequence of
operations occurs as the transfer switch retransfers to
the available normal source and signals the generator
set to shut down after a cooldown period.
1.4.3

Other Tests

Every Three Years
Test the wire insulation. Use the following procedure to
check for insulation breakdown and replace any faulty
components.
Note: Do not perform dielectric testing on the
equipment with control components in the circuit.
Wire Insulation Breakdown Test Procedure
1. Disconnect all power sources by performing the
service disconnect procedure. See Section 1.6 for
instructions. Disconnect the load from the transfer
switch by opening circuit breakers or switches
leading from the transfer switch. Disconnect the
transfer switch wiring harness from the controller at
connector P1.
TP-6745 7/10
DANGER
Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.
Testing live electrical circuits. Hazardous voltage or
current can cause severe injury or death. Have trained and
qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically
insulated probes and follow the instructions of the test
equipment manufacturer when performing voltage tests.
Observe the following precautions when performing voltage
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
electrically insulated mat. (3) Do not touch the enclosure or
components inside the enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)
2. Disconnect the controller components by using the
control circuit isolation procedure. See Section 1.7
for instructions.
3. Use a hi-pot tester or meggar to check the
insulation resistance
phase-to-neutral, and phase-to-ground if neutral
and ground are isolated. For a hi-pot tester, the
maximum potential is 500 VAC and the maximum
test time is 1 second.
4. Verify that the measured insulation resistance
exceeds 1.24 megohms (MΩ).
5. If the hi-pot tester indicates wire insulation
breakdown or if the measured resistance is less
than 1.24 MΩ, isolate the leakage current using an
instrument designed for this purpose. Replace the
faulty components.
Note: You may need to disconnect power
conductors from the lugs to isolate the
problem. If you disconnect the power
conductors,
operation and installation manual for
reconnection instructions.
Every Five Years
Check the normal and emergency source setpoint
calibration according to the procedures in Section 2.5,
System Settings.
Section 1 Scheduled Maintenance
phase-to-phase
see the transfer switch
and
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