DynaGen AST3225 User manual

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

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READ MANUAL BEFORE INSTALLING UNIT
Receipt of shipment and warranty return information
Upon receipt of shipment, carefully remove the unit from the shipping container and
thoroughly examine the unit for shipping damage. In case of damage, immediately
contact the carrier and request that an inspection report be filed prior to contacting the
COMPANY.
All returned items must be shipped prepaid and include a return material authorization
(RMA) number issued by the COMPANY. 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
warranty and no other warranty shall be implied.
For questions or comments regarding this product, contact:
DynaGen Technologies Inc.
Phone [phone]
Fax: [phone]
Email: [e-mail]
WEB SITE: www.dynagensystems.com
Manual for AST3225 Automatic Transfer Switch

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Table of Contents
1: GENERAL DESCRIPTION:
1:1 Switchgear 4
1:1:1 Specification 4
1:1:2 Operation 4
1:2 Relay Board Module 5
1:2:1 Sensing 5
Relay coil Sensing 5
Adjustable Voltage Sensing 5
1:2:2 System Operation 5
2: INSTALLATION INFORMATION: 6
2:1 General 6
2:2 Recommended Upstream Protection: 6
3:REPLACINGPARTS 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
6:2 Engine Exerciser 17
Manual for AST3225 Automatic Transfer Switch

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1: GENERAL DESCRIPTION
1:1 Switchgear:
The AST3225 transfer switch mechanism consists of a basic mechanical switching
assembly that can be configured to satisfy various application requirements. (UL listed
E200939 Switch Mechanism). This manual describes the AST3225-2 model. (General
Arrangement page 14)
1:1:1 Specifications for AST3225-2 model
Normal/Emergency/Neutral Lug Connections 300
MCM MA Load connections 320 MCM (Max Wire
Size)
VOLTAGE NORMAL
208/240
EMERGENCY
208/240
Amperage 225 225
Hz 60 60
Ph Single Single
Poles 2 2
Transfer Motor: 120V 60 HZ 2.3 amps thermally protected
Withstand/interrupting rating: symmetrical 10 KA. for loading at 100% of nameplate
current Enclosure: 24” wide x 30” high x 9” deep. NEMA 4.
1:1:2 Operation:
The AST3225 includes the suitable sensing circuitry for automatic transfer of an
electrical load to a stand-by power supply in the event of a drop or loss of voltage of any
or all phases of the normal power supply. Upon the restoration of the normal 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 voltage sensing connection points
for Utility Line sensing. Provision is also made for manual transfer of the power sources
if necessary. Instructions for the manual procedure are located on the operating arm of
the mechanism. The AST3225 mechanism is a lever-operated device controlled by a 120
volt unidirectional gear-motor.
The transfer motor drives a crank that in turn operates an aluminum lever arm, by sliding
a nylon slider between the top and bottom parts of the arm assembly. The lever, in turn,
operates the two switch handles by means of a unique spring and roller arrangement. The
travel position of the aluminum lever is detected by two micro switches, which in turn
disconnect power to the transfer motor, when appropriate.
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1:2 Relay Board Module:
The relay board provides means for automatic transfer of a utility source of power to an
emergency source of power, upon loss of the utility, and switches back again, upon
restoration of the utility. The relay board has no built in delays for transfer. Any required
delays must come from an external source (ie. engine controller, timer module).
1:2:1 Sensing:
The relay board module provides 2 types of voltage sensing:
i). Relay Coil Sensing:
When the slide switch, located on the relay module, adjacent to the 8 pin octal socket, is
in the ON or UP position, utility voltage sensing is provided by means of an on board
relay coil. The relay coil characteristics set the pick up and drop out of the main utility
source.
ii). Adjustable Voltage Sensing:
When the slide switch is in the OFF, or DOWN position, the on board relay coil is
bypassed, and voltage sensing is provide 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 5.20.
ADJUSTMENT PROCEDURE
Rotate the line voltage adjustment to the nominal line voltage feeding the transfer switch.
Measure the line to line voltage. If the voltage is up to 10% below the adjustable voltage
set point, and the LED on the monitor is illuminated, the adjustable voltage monitor is
working properly. The voltage sensor can also be factory set to customer specifications.
1:2:2 System Operation:
The relay board module has provisions for 12 and 24 VDC operation. The relay board
comes factory set for 12 VDC applications. Changing from 12 to 24 VDC will require
cutting the 2 jumper wires located next to the 5-position header.
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2: INSTALLATION INFORMATION
2:1 General
The basic AST3225 transfer switch includes all control wiring connections.
The electrical switchgear should be installed by a certified electrician, and all wiring
to/from the unit should agree with all applicable electrical codes, standards, and practices.
An engine controller or timing module (optional) is usually installed at the engine; this
installation can be performed by the electrician, or by a mechanic competent at engine
wiring. A diagram for wiring up a typical engine controller at the engine is included at
Section 5:4, Page 15
Interconnecting the engine controller or timer module controller to the transfer switch is
done simply with a 5-wire signal cable. We provide 50’ as a standard length with each
order, but any length, 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 into the appropriate
locations of the 5-pin connector supplied for the purpose. Then connect to the adaptor
harness. (Also supplied.)
2:2 Recommended Upstream Protection
The AST3225 Transfer Switch Mechanism has been approved for use with the following
upstream protective device:
MANUFACTURER CLASSIFICATION AMPERE
RATING
CATALOG
NUMBER
AMP-TRAP
GOULD SHAWMUT
CLASS J 300 A4J300
RECOMMENDED FUSE BLOCKS WITH BOX CONNECTORS FOR AMP-TRAP
CLASS J FUSES
CATALOG NUMBER
600 VOLTS OR LESS
FUSE
AMPERE
RATING 1 POLE 3 POLE
300 64031J 64033J
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3: REPLACING PARTS
The AST3225 transfer switch mechanism has been designed to allow all components to
be accessible and readily removable from the front of the back panel.
CAUTION When replacing any parts of the mechanism, isolate the transfer switch from
any possible source of power.
All AST3225 transfer switch mechanism hardware should be tightened sufficiently
before re-energizing the switch. 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 on page 13. All parts are available direct from the
factory. Be sure to state the model and serial number of the switch. These are located on
the arm label.
Manual for AST3225 Automatic Transfer Switch

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3:1 REPLACEMENT PARTS LIST
PARTS DESCRIPTION Ref. PARTS DESCRIPTION Ref.
No. No.
Washer #10 Flat 1 Outer Roller Spacer 53
Bolt 3/8"-16x2" grade 5 2 Spring Roller 54
Screw 6-32x1/2" machine binding head SS 3 Relay Module Wire Harness 55
Screw 6-32x3/8" machine pan head SS 4 Engine Exerciser Wire Harness 56
Washer 3/8" flat 13/16"OD zinc plated 5 Engine Controller Wire Harness 57
Nut 3/8"-16 hex SS 6 Engine Exerciser 58
Screw 10-24x3" machine round head zinc plated 7 Ground Strap 59
Washer #6 flat SS 8 Label Package 60
Screw 4-40x 5/8 machine round head zinc plated Phillips 9 Relay Module 61
Flat Head Screw #6-32 x 1/2" Phillips zinc plated 10 Engine Exerciser Bracket 62
Screw 8-32x5/16" machine binding head SS 11 Screw 1/4" x3/4” hexagon head 63
Washer #8 spring lock SS 12 Relay – 12VDC or 24 VDC 64
Screw 1/4"-20x1/2" set hex socket cup point SS 13 Adjustable Voltage Monitor 65
Spring pin 1/8"x1 3/8" coiled 14 M-6 Metric Hexagon Nut 66
5/16"-18 x 5/8" socket head cap screw 15 # 6 x ¼” 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 Support Bracket 77
Nut 1/4"-20 hex 22 Pivot Support Bracket 78
Washer #10 spring lock zinc plated 23 Neutral Block Insulator 80
Screw 10-24x5/8" pan head zinc plated 24 Neutral Block Plate 81
Screw 6-32x1/4" machine binding head SS 25 Cable 82
Switch 26 Back Panel Detail 83
Gear Motor 27 Enclosure Detail 84
Terminal Lug 28 Lever Arm Angle - Lower 85
Molded Case Switch 30 Limit Switch Spacer 86
Terminal Lug 31 Limit switch cam 87
Actuating Arm Slider 48 Aluminum Crank Block 88
Slider Pin 49 Squeeze Release Latch 92
Actuating Arm Pivot Block 50 Screw #6-32 x1" Machine Binding Head 94
Spring Detail 51 Nylon Spacer - #6x1/2" 95
Inner Roller Spacer 52
Manual for AST3225 Automatic Transfer Switch

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3:2 MAIN SWITCH REMOVAL AND REPLACEMENT
To remove the main normal or emergency switches, first electrically isolate the
transfer switch from all power sources.
a) Disconnect all cables and wiring from the switch terminals.
b) Open the cover on the operating arm, remove the pin slider and close the
cover.
c) Remove the switch operating arm assembly by removing the four screws
securing the pivot bracket to the back panel and lift the arm assembly
complete with bracket from the back panel.
d) The individual switches can now be readily unfastened and removed from
the back panel.
Replacement is the reverse of the above procedure. Note when replacing
the arm assembly, ensure that the switches are set one “off” and one “on”
and that the rollers 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 the terminal block. Strip each wire ¾ of an inch, and attach the
corresponding leads from the new motor with wire connectors approved
for 18 gauge wire. Remove the arm assembly as previously described.
– Remove four screws securing the motor bracket to the back panel.
– Lift the assembly out of the transfer switch.
– Remove the crank and cam assembly by loosening the set screw in the cam
arm.
– Remove four screws securing the motor to the underside of the motor
bracket. The motor can now be removed.
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Replacement is the reverse of procedure 3.3. Note that the crank arm must be positioned
flush with the end of the motor shaft, and the set screw opposite the flat surface on the
shaft.
3:4 MECHANICAL LIMIT SWITCH ADJUSTMENT
The limit switches controlling the normal and emergency positions of the main
switches, have been factory set to a clearance of 0.020” between the face of the
switch and the limit switch cam, to ensure continued reliable operation. Should it
become necessary to adjust this gap, in the event of replacing a limit switch for
example, 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 switch cam and
the operating plunger of the switch. Rotate the limit switch about the pivot
screw to establish the 0.020” clearance. Tighten the clamp screw and pivot
screw.
d) Rotate the limit switch cam by hand to check the switch operation and
readjust if necessary
e) Replace the pin slider and close the cover.
Manual for AST3225 Automatic Transfer Switch