DynaGen AST3225, Installation And User Manual

Page 1: ...AST3225 Automatic Transfer Switch Installation and User Manual for the AST3225 2 Automatic Transfer Switch Full Version File AST3225 2rev1 6 doc May 9 2003 ...

Page 2: ... RMA forms are available by contacting the COMPANY Limited Warranty The COMPANY DynaGen Technologies Inc warrants the product with specifications as explained herein The COMPANY shall repair or replace any defective materials or workmanship f o b the Company s factory which prove to be defective under normal and proper use within three year s from the date of shipment This constitutes the only war...

Page 3: ...commended Upstream Protection 6 3 REPLACING PARTS 7 3 1 Parts List 8 3 2 Main Switch Removal and Replacement 9 3 3 Motor Removal and Replacement 9 3 4 Mechanical Limit Switch Adjustment 10 4 RECOMMENDED MAINTENANCE 11 5 DRAWINGS 5 1 Limit Switch Replacement 12 5 2 Mechanical Assembly 13 5 3 General Arrangement 14 5 4 Wiring Harness Connections 15 6 FIELD SET UP 6 1 Locking Mechanism Optional 16 6 ...

Page 4: ...ormal supply the electrical load is automatically re transferred to the normal power supply The transfer motor utilizes power from the source to which the electrical load is being transferred The mechanism provides a positive mechanical interlock to prevent both switches from being closed at the same time The AST3225 also incorporates the basic actuating motor control switches terminal blocks and ...

Page 5: ...e by a UL approved voltage sensing module which plugs into the 8 pin octal socket The adjustable voltage monitor is a single set point voltage monitor Input voltages 10 below the set point range will cause the output contacts to de energize unit is adjustable from 190 240 VAC The adjustable drop out relay recommended for use with the AST3225 Automatic Transfer Switch is the Symcom 201 200 SP T Rev...

Page 6: ...h in 25 increments can be provided upon request for a nominal charge The cable assembly has the transfer switch connector already mounted Simply install it in the Relay Board receptacle pass the bare end through an appropriately located hole in the enclosure and run it to the engine controller or timer module At the controller trim the wire to length strip the color coded wires and insert them int...

Page 7: ... The following table provides suggested tightening torques Screw Size Tightening Torque in LB 4 5 6 10 8 20 10 40 1 4 90 3 8 300 NOTE For satisfactory performance the switch terminal lugs must be securely fastened to the terminal strips 90 in LB min Torque lugs screws to 200 in LB Replacement parts should be identified with reference to the Parts List on page 8 and the Mechanical Assembly Drawing ...

Page 8: ... 8 x1 3 8 coiled 14 M 6 Metric Hexagon Nut 66 5 16 18 x 5 8 socket head cap screw 15 6 x Aluminum Spacer 67 Screw 10 32x1 4 SOC HD set SS 16 6 32 Hexagon Nut 69 Washer 5 16 spring lock 17 Washer Nylon Shoulder 72 Washer 6 spring lock SS 18 Lever Arm Angle Upper 73 Spacer 6 32 1 1 2 aluminum 19 Lever Arm Cover Plate 74 Screw 1 4 20x1 flat head 20 Slider Cover 76 Washer 1 4 spring lock 21 Motor Supp...

Page 9: ...lers on the arm springs equally straddle the switch operating levers Tighten the pivot bracket screws equally to ensure controlled deflections of the arm springs 3 3 MOTOR REMOVAL AND REPLACEMENT Electrically isolate the transfer switch from all power sources Note the wire connections to the 12 position terminal connector Cut the motor connection wires white and black approximately 3 inches from t...

Page 10: ...the following procedure is recommended see diagram page 12 a Electrically isolate the transfer switch from all power sources Loosen the pivot screw and clamp screw to enable the limit switch to rotate about the pivot screw b Open the cover on the operating arm and remove the pin slider to allow the limit switch cam to be rotated manually c Insert a 0 020 feeler gauge between the face of the limit ...

Page 11: ...pect all terminals load line and control and all fasteners for tightness Test the transfer switch operation upon initial installation in both the motor and manual modes Periodically check for freedom of movement of the mechanism hidden dirt or corrosion and any excessive wear on the mechanical operating parts Clean or replace parts when necessary Do not attempt to remove the arm assembly by loosen...

Page 12: ...12 5 1 LIMIT SWITCH ADJUSTMENT Manual for AST3225 Automatic Transfer Switch ...

Page 13: ...13 5 2 AST3225 MECHANICAL ASSEMBLY Manual for AST3225 Automatic Transfer Switch ...

Page 14: ...14 5 3 AST3225 GENERAL ARRANGEMENT Manual for AST3225 Automatic Transfer Switch ...

Page 15: ...15 5 4 Wiring Harness and Control Module Connections Manual for AST3225 Automatic Transfer Switch ...

Page 16: ...front of the enclosure remove the quarter turn insert rubber gasket and flat washer 5 Remove the lock nut located on the back of the enclosure door 6 On the back of the enclosure door gently tap the quarter turn latch housing until it is free from the door NOTE carefully observe how the quarter turn latch housing is inserted in the door as it has to be put back in the door in the exact same manner...

Page 17: ...he program change an existing exercise cycle or start a new program The MODE SWITCH located in the upper left corner can start the generator manually exercise the generator automatically or disable the exerciser function The push buttons below the clock display are used to program the exercise day time and duration The SKIP BUTTON is used to ignore an exercise day The RESET BUTTON initializes the ...

Page 18: ... the MINUTE button m repeatedly until the minute of the present hour is displayed such as AM 5 30 or PM 5 30 7 Move the SET switch slider to the run position The present time is displayed with the clock colon blinking in one second intervals The arrow appears continuously under the present day 8 Move the SET switch slider to the program position P in a circle The default time for starting an exerc...

Page 19: ...ave any combination of on off cycles Normally the exerciser time clock will only require one on off cycle once per week The programming steps given above describe how to exercise the generator once a week EXAMPLE Suppose that the desirable day and time for exercising the generator is Saturday at 5 00 AM Move the slider of the SET SWITCH to the right P in circle position Press the DAY BUTTON 1 7 re...