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eLibrary >
ANSI/NEMA KS 3-2023 Guidelines for Inspection and Preventive Maintenance of Switches Used in Commercial and Industrial Applications >
ANSI/NEMA KS 3-2023 Guidelines for Inspection and Preventive Maintenance of Switches Used in Commercial and Industrial Applications, 2023
- 1 General [Go to Page]
- 1.1 Scope
- 1.2 Referenced Standards
- 2 Safety Procedures [Go to Page]
- 2.1 Warning [Go to Page]
- 2.1.1 Switch Testing
- 2.1.2 Test Equipment
- 2.2 Safety Procedure
- 2.3 Reinstallation Safety Procedure
- 3 Guidelines [Go to Page]
- 3.1 To Avoid Damaged or Otherwise Inoperable Switches Being Inadvertently Returned to Service
- 3.2 Guidance Regarding Inspection and Preventive Maintenance Procedures
- 3.3 For Information Regarding Switch Performance and Application
- 3.4 Water-damaged Switches
- 3.5 Switch Inspection Once Each Year
- 4 Inspection Procedures [Go to Page]
- 4.1 General
- 4.2 Exposed Surfaces Temperature Check [Go to Page]
- 4.2.1 Purpose
- 4.2.2 Procedure
- 4.2.3 Results
- 4.3 Inspection of Enclosure Interior [Go to Page]
- 4.3.1 Purpose
- 4.3.2 Procedure [Go to Page]
- 4.3.2.1 After being properly isolated, verify that the switch has been properly applied within its marked ratings. If the switch has not been applied within its ratings, it should be replaced with a switch suitable for the application.
- 4.3.2.2 Examine the switch surfaces for the presence of dust, dirt, soot, grease, or moisture. If such contamination is found, the surfaces should be cleaned. Refer to 36T5.2.2.136T for cleaning and precautionary instructions.
- 4.3.2.3 Examine the switch bases for cracks. The integrity of the base is important in withstanding the stresses imposed during operation. Switches should be replaced if cracks are found.
- 4.3.2.4 Verify that the conductors are of the correct size and type for the application. Visually check all electrical connections to the switch to be certain that such connections are clean and secure. Loose or contaminated connections increase elect...
- 4.3.2.5 Examine the switch for evidence of a high-short-circuit closing operation. Any of the following observations will warrant performing the Section 6 test procedures or the replacement of the switch. In some cases, switch interior renewal parts c...
- 4.3.2.6 Reinstallation Procedure
- 5 Preventive Maintenance [Go to Page]
- 5.1 General
- 5.2 Environmental Evaluation [Go to Page]
- 5.2.1 Purpose
- 5.2.2 Procedure [Go to Page]
- 5.2.2.1 After being properly isolated, examine the switch surfaces for dust, dirt, soot, or moisture. If evidence of contaminates or moisture is found, or more than a thin film of dust, dirt, or soot is seen, the switch should be cleaned as suggested ...
- 5.2.2.2 Examine the switch and terminations for signs of overheating as described in 4.3.2.4. If such evidence is found, the following maintenance steps should be performed. [Go to Page]
- 5.2.2.2.1 Copper switch terminals and connecting straps (wire connectors and bus bars) can normally be cleaned. They should be carefully disassembled, cleaned, and dressed, following the manufacturer’s instructions. All metal and abrasive particles sh...
- 5.2.2.2.2 Aluminum wire connectors and bus bars cannot be cleaned or repaired; therefore, they must be replaced.
- 5.2.2.2.3 If wire conductors are damaged, the damaged lengths of the conductors should be cut off before reinstalling the conductors (see 5.4).
- 5.3 Fuse Provisions
- 5.4 Wire Connectors [Go to Page]
- 5.4.1.1 Examine wire connectors. If the wire connectors appear to be in good condition, they may be reused. If the connectors, screws, or their plating appear worn or damaged, or there is evidence of cross-threading or binding, the connector assembly ...
- 5.4.1.2 If the wire conductors are damaged, the damaged wires should be repaired or replaced.
- 5.4.1.3 When required, an oxide-inhibiting compound should be applied.
- 5.4.1.4 All wire connectors should be torqued in accordance with the nameplate marking or the switch manufacturer's instructions.
- 5.5 Reinstallation Procedure
- 6 Test Procedures [Go to Page]
- 6.1 General
- 6.2 Mechanical Operation Test [Go to Page]
- 6.2.1 Purpose
- 6.2.2 Equipment
- 6.2.3 Procedure [Go to Page]
- 6.2.3.1 After disconnecting and locking out all power, operate the switch ON and OFF two or three times. The switch handle should operate smoothly without binding.
- 6.2.3.2 Using an ohmmeter or other indicating device, verify that all switch contacts are open when the handle is in the OFF position and closed when the handle is in the ON position.
- 6.2.3.3 For switches that are provided with mechanical trip provisions (generally indicated by a test button), operate the tripping means according to the manufacturer's instructions. With the switch in the tripped position, verify that the contacts a...
- 6.2.4 Results
- 6.2.5 Reinstallation Procedure
- 6.3 Insulation Resistance Test [Go to Page]
- 6.3.1 Purpose
- 6.3.2 Equipment
- 6.3.3 Procedure [Go to Page]
- 6.3.3.1 After disconnecting and locking out all power supplying the device to be tested, remove the switch from the electrical system. In cases where the switch can be safely isolated/disconnected from line and load connections as installed, the test ...
- 6.3.4 Test [Go to Page]
- 6.3.4.1 All exposed metal parts except line, load, and accessory terminals should be electrically connected together.
- 6.3.4.2 Using an insulation resistance tester, apply a voltage of at least 500 volts to determine the resistance. Voltage is to be applied as follows.
- 6.3.5 Results
- 6.3.6 Reinstall Switch
- 6.3.7 Reinstallation Procedure
- 6.4 Individual Pole Resistance Test (Millivolt Drop) [Go to Page]
- 6.4.1 Purpose
- 6.4.2 Equipment [Go to Page]
- 6.4.2.1 This test should be conducted using a 24-volt (or less) direct current power supply capable of supplying the rated current of the switch. For a switch rated higher than 500 amperes, the power supply should be capable of delivering no less than...
- 6.4.2.2 If the above equipment is not available for field tests, a digital low-resistance ohmmeter (DLRO), or 4-point tester capable of 10 to 100 amperes (DC) may be used.
- 6.4.3 Procedure [Go to Page]
- 6.4.3.1 After being properly isolated, remove the switch from the enclosure. In cases where the switch can be safely isolated/disconnected as installed, the test may be performed with the switch in its equipment.
- 6.4.4 Test [Go to Page]
- 6.4.4.1 The test is performed as follows: [Go to Page]
- 6.4.4.1.1 Apply test current across a pole equal to the switch rating (or 500 amperes minimum for a switch rated in excess of 500 amperes). Record the millivolt drop and the test current. Do not maintain current for more than 1 minute. If this equipme...
- 6.4.4.1.2 Apply test current across a pole of 10 amperes, or the ampere rating of the switch, for a switch rated less than 100 amperes. For a switch rated more than 100 amperes, apply a test current across a pole of 100 amperes. Record the millivolt d...
- 6.4.4.1.3 De-energize the test circuit. Manually operate the switch to the OFF and then ON positions.
- 6.4.4.1.4 Repeat steps 6.4.4.1.1 and 6.4.4.1.2 for a total of three readings on the pole being tested.
- 6.4.4.1.5 Repeat steps 6.4.4.1.1 through 6.4.4.1.3 for each of the remaining poles of the switch.
- 6.4.5 Results
- 6.4.6 Reinstall Switch
- 6.4.7 Reinstallation Procedure
- 7 Accessory Device Test Procedures [Go to Page]
- 7.1 General
- 7.2 Shunt Trip Release Tests [Go to Page]
- 7.2.1 Purpose
- 7.2.2 Equipment
- 7.2.3 Procedure [Go to Page]
- 7.2.3.1 After disconnecting and locking out all power, isolate the shunt trip solenoid leads from the control circuit for testing.
- 7.2.3.2 Connect a test power supply to the terminals (or leads) of the shunt trip release device.
- 7.2.3.3 Operate the switch to the ON position.
- 7.2.3.4 Set the power supply voltage to 75% of the rated voltage of the shunt trip and energize. The switch should open. If the switch with shunt trip release is used in a ground fault relay system, use 55% of the rated voltage instead of 75% of the r...
- 7.2.3.5 When the test is completed, turn off the test power supply, disconnect it from the shunt trip release device terminals (or leads), and reconnect the control circuit wires to the shunt trip release device terminals (or leads). If an under-volta...
- 7.2.4 Results
- 7.2.5 Reinstallation Procedure
- 7.3 Electrical Operator Tests [Go to Page]
- 7.3.1 Purpose
- 7.3.2 Equipment
- 7.3.3 Procedure [Go to Page]
- 7.3.3.1 After disconnecting and locking out all power, remove the control circuit wires from the terminals of the electrical operator.
- 7.3.3.2 Set test power supply to the rated voltage of the electrical operator and connect to the terminals of the electrical operator marked “common” and “close” or “on.”
- 7.3.3.3 With the switch in the OFF position, turn on the test power supply. The switch contacts should close.
- 7.3.3.4 Turn the test power supply off. Disconnect its leads to the electrical operator.
- 7.3.3.5 Connect the test power supply leads to the terminals of the electrical operator marked “common” and “open” or “off.”
- 7.3.3.6 With the switch in the ON position, turn on the test power supply. The switch contacts should open.
- 7.3.3.7 When the test is completed, turn off the test power supply, disconnect it from the electrical operator terminals, and reconnect the control circuit wires to the electrical operator terminals.
- 7.3.4 Results
- 7.3.5 Reinstallation Procedure
- 7.4 Auxiliary Switch Tests [Go to Page]
- 7.4.1 Purpose
- 7.4.2 Equipment
- 7.4.3 Procedure [Go to Page]
- 7.4.3.1 Remove the control circuit wires from the terminals (or leads) of the auxiliary switch(es).
- 7.4.3.2 Starting with the main switch in the OFF position, use an ohmmeter or continuity tester connected to the terminals (or leads) of each auxiliary switch to verify that its contact position (open or closed) is in agreement with the wiring diagram...
- 7.4.3.3 Connect the ohmmeter or low-voltage continuity tester to the terminals (or leads) of one auxiliary switch to monitor the contact.
- 7.4.3.4 Operate the main switch to the ON position. The auxiliary switch contact should change position.
- 7.4.3.5 Repeat 7.4.3.2 through 7.4.3.4 for each auxiliary switch.
- 7.4.3.6 When the test is completed, reconnect the control circuit wires to the switch auxiliary switch terminals (or leads). If an under-voltage trip release device was connected, refer to 7.2.3.5 for instructions.
- 7.4.4 Results
- 7.4.5 Reinstallation Procedure [Go to Page]
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