Kraft_Start-up_Form_Editable_(1)_0001.pdf

Authorized Kohler Representative Performing Startup

Telephone

Company Name

Address

City

State

ZIP/Postal Code

Country

Owner Name/Unit Location

Telephone

Company Name/Owner

Address of Unit Location

City

State

ZIP/Postal Code

Country

Round-trip miles from nearest authorized Kohler servicing distributor/dealer to the power system equipment:

Generator Set and Engine Nameplate Information

Generator Set. No 1 Engine No. 1 Generator Set No. 2 Engine No. 2

Serial No.

Model No.

Spec. No

Application Information (one item in each column must be checked) q Industrial q Residential/Commercial q Mobile/Towable/Trailer-Mounted q Stationary q Prime q Rental q Standby

Transfer Switch and Switchgear Nameplate Information

ATS No. 1 ATS No. 2 ATS No. 3 ATS No. 4 Switchgear

Serial No.

Spec. No

Contractor Serial No.

Model No.

Kohler Representative’s Name (print) Owner Representative’s Name (print)

Kohler Representative’s Signature and Date Owner Representative’s Signature and Date

mo. _______ day _______ yr. _______ mo. _______ day _______ yr. _______

K-625 (1/13)

Follow the startup checklist on the back of this form. Then complete the form.

This form is required for coverage under the Kohler limited warranty and must be completely filled out at the time of initial startup. Representatives of the distributor/dealer and owner must sign the notification form. Signing this form represents acceptance of the unit and that all information on the startup form is correct. Please submit registration to Kohler Co.

using the online warranty processing system. Users that do not have access to the online warranty site should mail a copy to Kohler.

Startup Notification

Startup Date

mo. __________ day __________ yr. __________

199 Wildwood, P.O. Box 2189, Woburn, MA 01888-0389, Tel • 781-938-9100 / Fax • 781-933-7812 • www.kraftpower.com

* Some models with an Engine Electronic Control Module (ECM) may limit or prohibit adjusting the engine speed or testing shutdowns.

Refer to appropriate documentation available from the manufacturer.

Generator Set/Transfer Switch Startup Checklist

This document has generic content and some itemsmaynot apply to some applications. Check only the items that apply to the specific application.

Read and understand all of the safety precautions found in the Operation and Installation Manuals. Complete the Installation Checklist before performing the initial startup checks. Refer to Service Bulletin 616 for Warranty Startup Procedure Requirements regarding generator set models with ECM-controlled engines.

Yes

Does Not Apply

� � 1. Verify that the engine is filled with oil and the cooling system is filled with coolant/antifreeze.

� � 2. Prime the fuel system.

� � 3. Open all water and fuel valves. Temporarily remove the radiator cap to eliminate air in the cooling system.

Replace radiator cap in step 21.

� � 4. Place the generator set master switch in the OFF/RESET position. Observe Not-in-Auto lamp and alarm, if equipped, on the controller.

� � 5. Press the lamp test, if equipped on controller. Do all the alarm lamps on the panel illuminate?

� � 6. Open the main line circuit breakers, open the safeguard breaker, and/or remove fuses connected to the generator set output leads.

� � 7. Turn down the speed control (electronic governor) or speed screw (mechanical governor).*

� � 8. Verify the presence of lube oil in the turbocharger, if equipped. See the engine and/or generator set operation manual.

� � 9. Place the generator set master switch in the RUN position. Allow the engine to start and run for several seconds.

� � 10. Verify that the day tank, if equipped, is energized.

� � 11. Place the generator set master switch in the OFF/RESET position. Check for oil, coolant, and exhaust leaks.

� � 12. Turn on the water/oil heaters and fuel lift pumps.

� � 13. Check the battery charger ammeter for battery charging indication.

� � 14. Place the generator set master switch in the RUN position. Verify whether there is sufficient oil pressure.

Check for oil, coolant, and exhaust leaks.

� � 15. Close the safeguard circuit breaker. Adjust the engine speed to 50/60 Hz if equipped with an electronic governor or to 52.8/63 Hz if equipped with a mechanical governor.*

� � 16. If the speed is unstable, adjust according to the appropriate engine and/or governor manual.*

� � 17. Adjust the AC output voltage to match the load voltage using the voltage adjusting control. See the generator set/controller operation manual.

� � 18. Allow the engine to reach normal operating coolant temperature.

� � 19. Check the operating temperature on city water-cooled models and adjust the thermostatic valve as necessary.

� � 20. Manually overspeed the engine to cause an engine shutdown (68-70 Hz on 60 Hz models and 58-60 Hz on 50 Hz models). Place the generator set master switch in the OFF/RESET position.*

� � 21. Check the coolant level, add coolant as necessary, and replace the radiator cap. Verify that all hose clamps are tight and secure.

� � 22. Place the generator set master switch in the RUN position.

� � 23. Verify the engine low oil pressure and high coolant temperature shutdowns.*

� � 24. Check the overcrank shutdown.*

� � 25. Place the generator set master switch in the OFF/RESET position.

� � 26. Open the normal source circuit breaker or remove fuses to the transfer switch.

� � 27. Disconnect the power switching device and logic controller wire harness at the inline disconnect plug at the transfer switch.

� � 28. Manually transfer the load to the emergency source.

Yes

Does Not Apply

� � 29. Close the normal source circuit breaker or replace fuses to the transfer switch.

� � 30. Check the normal source voltage, frequency, and phase sequence on three-phase models. The normal source must match the load.

� � 31. Open the normal source circuit breaker or remove fuses to the transfer switch.

� � 32. Manually transfer the load to the normal source.

� � 33. Close the generator set main line circuit breakers, close the safeguard breaker, and/or replace the fuses connected to the transfer switch.

� � 34. Place the generator set master switch in the RUN position.

� � 35. Check the generator set voltage, frequency, and phase sequence on three-phase models. The generator set must match normal source and load.

� � 36. Place the generator set master switch in the OFF/RESET position.

� � 37. Open the generator set main line circuit breakers, open the safeguard breaker, and/or remove the fuses connected to the transfer switch.

� � 38. Reconnect the power switching device and logic controller wire harness at the inline disconnect plug at the transfer switch.

� � 39. Close the normal source circuit breaker or replace fuses to the transfer switch. Place the generator set master switch to the AUTO position.

� � 40. Close the generator set main line circuit breakers, close the safeguard breaker, and/or replace the fuses connected to the transfer switch.

� � 41. Place the transfer switch in the TEST position (load test or open normal source circuit breaker). NOTE: Obtain permission from the building authority before proceeding. This procedure tests transfer switch operation and connects building load to generator set power.

� � 42. Readjust frequency to 50 or 60 Hz with total building loads.*

� � 43. Verify that the current phase is balanced for three phase systems.

� � 44. Release the transfer switch test switch or close the normal circuit breaker. The transfer switch should retransfer to the normal source after appropriate time delay(s).

� � 45. Allow the generator set to run and shut down automatically after the appropriate cool down time delay(s).

� � 46. Set the plant exerciser to the customer’s required exercise period, if equipped.

� � 47. Verify that all options on the transfer switch are adjusted and functional for the customer’s requirements.

� � 48. If possible, run the building loads on the generator set for several hours or perform the load bank test if required.

� � 49. Verify that all the wire connections from the generator set to the transfer switch and optional accessories are tight and secure.

� � 50. Verify that the customer has the appropriate engine/generator set and transfer switch literature.

Instruct the customer in the operation and maintenance of the power system.

� � 51. Fill out the startup notification at this time and send the white copy to the Generator Warranty Dept. Include the warranty form if applicable.

Generator Set/Transfer Switch Installation Checklist

This document has generic content and some items may not apply to some applications. Check only the items that apply to the specific application. Read and understand all of the safety precautions found in the Operation and Installation Manuals. Make the following installation checks before performing the Startup Checklist.

Note: Use this form as a general guide, along with any applicable codes or standards. Comply with all applicable codes and standards.

Improper installation voids the warranty.

Equipment Room or Weather Housing

Yes

Does Not Apply

� � 1. Is the equipment installed in a fire-resistant room (made of non-combustible material) or in an outdoor weather housing?

� � 2. Is there adequate clearance between the engine and floor for service maintenance?

� � 3. Is there emergency lighting available at the equipment room or weather housing?

� � 4. Is there adequate heating for the equipment room or outdoor weather housing?

� � 5. Is the equipment room clean with all materials not related to the emergency power supply system removed?

� � 6. Is the equipment room protected with a fire protection system?

Engine and Mounting

� � 7. Is the mounting surface(s) properly constructed and leveled?

� � 8. Is the mounting surface made from non-combustible material?

� � 9. Was the generator-to-engine alignment performed after attaching the skid to the mounting base?

Generator sets with two-bearing generators require alignment.

Lubrication

� � 10. Is the engine crankcase filled with the specified oil?

Cooling and Ventilation

� � 11. Is the cooling system filled with the manufacturer’s specified coolant/antifreeze and purged of air?

� � 12. Is there adequate inlet and outlet air flow (electric louvers adjusted and ventilation fan motor(s) connected to the corresponding voltage)?

� � 13. Is the radiator duct properly sized and connected to the air vent or louver?

� � 14. Are flexible sections installed in the cooling water lines?

Fuel

� � 15. Is there an adequate/dedicated fuel supply?

� � 16. Are the fuel filters installed?

� � 17. Are the fuel tanks and piping installed in accordance with applicable codes and standards?

� � 18. Is there adequate fuel transfer tank pump lift capacity and is the pump motor connected to the corresponding voltage?

� � 19. Is the fuel transfer tank pump connected to the emergency power source?

� � 20. Are flexible fuel lines installed between the engine fuel inlet and fuel piping?

� � 21. Is the specified gas pressure available at the fuel regulator inlet? Static PSI Starting PSI Running PSI

� � 22. Does the gas solenoid valve function?

� � 23. Are the manually operated fuel and cooling water valves installed allowing manual operation or bypass of the solenoid valves?

Exhaust

� � 24. Is the exhaust line sized per guidelines and does it have flexible connector(s)? Is the flexible connector(s) straight?

Yes

Does Not Apply

� � 25. Is there an exhaust line condensate trap with a drain installed?

� � 26. Is the specified silencer installed and are the hanger and mounting hardware tightened?

� � 27. Is a heat-isolating thimble(s) installed at points where exhaust lines pass through combustible wall(s) or partition(s)?

� � 28. Is the exhaust line free of excessive bends and restrictions? Is the backpressure within specifications?

� � 29. Is the exhaust line installed with a downward pitch toward the outside of the building?

� � 30. Is the exhaust line protected from entry by rain, snow, and animals?

� � 31. Does the exhaust system outlet location prevent entry of exhaust gases into buildings or structures?

� � 32. Are individuals protected from exposure to high temperature exhaust parts and are hot parts safety decals present?

AC Electrical System

� � 33. Does the nameplate voltage/frequency of the generator set and transfer switch match normal/utility source ratings?

� � 34. Do the generator set load conductors have adequate ampacity and are they correctly connected to the circuit breakers and/or the emergency side of the transfer switch?

� � 35. Are the load conductors, engine starting cables, battery charger cables, and remote annunciator leads installed in separate conduits?

� � 36. Is the battery charger AC circuit connected to the corresponding voltage?

Transfer Switch, Remote Control System, Accessories

� � 37. Is the transfer switch mechanism free of binding?

Note: Disconnect all AC sources and operate the transfer switch manually.

� � 38. Are the transfer switch AC conductors correctly connected? Verify lead designations using the appropriate wiring diagrams.

� � 39. Is all other wiring connected, as required?

Batteries and DC Electrical System

� � 40. Does the battery(ies) have the specified CCA rating and voltage?

� � 41. Is the battery(ies) filled with electrolyte and connected to the battery charger?

� � 42. Are the engine starting cables connected to the battery(ies)?

� � 43. Do the engine starting cables have adequate length and gauge?

� � 44. Is the battery(ies) installed with adequate air ventilation?

� � 45. Starting Battery(ies) Voltage VDC

Special Requirements

� � 46. Is the earthquake protection adequate for the equipment and support systems?

� � 47. Is the equipment protected from lightning damage?

NFPA 110-1.5 building LT (1.5 hours loaded – record start delays on checklist) NFPA 110- 2 hour LBT 7. 13.4.1 (30%for 30min.50% for 30 min.100 % for 60 min) JCO-EC.02.05.07EP#7- 4 hour LBT (4 -hours minimum 30%) KW = volts x amps x 1.73 x pf / 1000 (3-phase power)

Tested By____________________________________ Witness_________________________________ Date______________________

NOTE: ALL NFPA/JCO LBT REPORTS MUST HAVE LOADED TIMES ONLY – DO NOT START RECORDING DATA UNTIL LOADED Reference # Field Test Report For:

Time in Minutes 0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 Lube Oil Pressure (PSI) Jacket Water Temp (oF) DC Charge (Volts) Frequency (Hertz) AC Volts: Phase 1-2 AC Volts: Phase 2-3 AC Volts: Phase 3-1 AC Amps: Phase 1 AC Amps: Phase 2 AC Amps: Phase 3 Calculated Kw Ambient Temp (oF)

FLA @ 1PF

Model LOP set at (psi) Antifreeze Installed & Checked Serial # HWT set at (oF) For oF Rating: KW KVA OS set at (HZ) Lube Oil Installed & Level Checked 60 HZ 0.8 PF OC set at (sec.) Jacket Water Heater Operating 1800rpm Volts Cycle Crank Rest (sec.) Daytank Pump Operation Checked FLA @ 0.8 PF: HOT set at (oF) Battery Charger Operating TDES: sec Water Heater Thermostat set (oF) Remote Start Contacts Checked Crank to Start TD: sec Low Oil Pressure Prewarn set (psi) Annunciator Contacts Checked Start to Op Speed TD: Hot Water Prewarn set (oF) Alarm Horn Function TD to stable \ Emgcy: Check Hoses and Clamps LBVAR Set _______VDC TDEN TDC Unit in Auto

HBVAR Set _______ VDC

2: Off