DynaGen Optimal Series User manual

Optimal Series
Automatic Transfer Switch
Installation and User Manual for the
OPT2600 Automatic Transfer Switch
Full Version
File: OPT2600 Rev1.4.doc
Nov. 5, 2004

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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.
We welcome your comments and suggestions. Please contact us at:
DynaGen Technologies Inc.
Phone: [phone]
[phone]
Fax: [phone]
Email: [email protected]
WEB SITE: www.dynagen.ca
User Manual for the OPT2600 Series Automatic Transfer Switch

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Table of Contents
1: GENERAL DESCRIPTION 4
1:1 Switchgear 4
1:1:1 Specification 4
1:1:2 Operation 5
1:2 Relay Control Module 6
1:2:1 Sensing 6
Adjustment Procedure 6
1:2:2 System Operation 7
2: INSTALLATION INFORMATION 7
2:1 General 7
2:2 Recommended Upstream Protection: 7
2:3 Open Type transfer Switches: 8
2:4 Remote start switch installation: 9
3: REPLACING PARTS 9
3:1 Replacement Parts List 10
3:1 Main Switch Removal and Replacement 11
3:2 Motor Removal and Replacement 12
4: MANUAL TRANSFER OF MECHANISM 12
5: RECOMMENDED MAINTENANCE 13
6: DRAWINGS
6:1 Mechanical Assembly 14
6:2 General Arrangement 15
6:3 OPT2600- 2-120/240V Wiring Diagram 16
6:4 OPT2600- 3-208/240V Wiring Diagram 17
6:5 OPT2600- 3-480V Wiring Diagram 18
6:6 OPT2600- 3-600V Wiring Diagram 19
7: ENGINE EXERCISER 20
User Manual for the OPT2600 Series Automatic Transfer Switch

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1: GENERAL DESCRIPTION
1:1 Switchgear:
The OPT2600 transfer switch mechanism consists of a basic mechanical switching
assembly that can be configured to satisfy various application requirements. This manual
describes the following models:
OPT2600-2-120/240V-E
OPT2600-3-208/240V-E
OPT2600-3-480V-E
OPT2600-3-600V-E
1:1:1 Specifications for OPT2600 models
Please refer to the following Optimal Series Automatic Transfer Switch rating label
located on switch for proper ratings associated with your specific model.
SERIAL NUMBER
RATING: VOLTS
AMPS
SYSTEM VOLTS
MODEL NUMBER
MANUF. DATE
HZ
PHASE
PHASE
WARNING: Never exceed the voltage and amperage ratings of the
transfer switch.
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1:1:2 Operation:
The OPT2600 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 normally
required time delay functions are all included in the Timer Module package.
The transfer motor utilizes power from the source to which the electrical load is being
transferred. The mechanism provides an optional mechanical interlock to prevent both
switches from being closed at the same time. The OPT2600 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. The OPT2600 mechanism is a lever-operated device controlled by a 120
volt, 60 HZ 3 amps thermally protected unidirectional gear-motor.
The transfer motor drives a crank that in turn operates a lever arm. The lever, in turn,
operates the two switch handles by means of guided roller assemblies. The roller
assemblies are independently adjusted by either hexagon nuts or rollers. The travel
position of the lever arm is detected by two micro switches, which in turn disconnect
power to the transfer motor, when appropriate.
The dipswitch located on the TSC3A is used to set the load / no load setting (refer to
TSC3A user manual). When switch location #3 is on, the system is configured for a load
condition. When switch location #3 is off, the unit is configured for a no load condition.
This setting applies to the remote test switch and engine exercise option only. This setting
allows for exercising the transfer switch under a loaded or a no load condition.
When testing or exercising the transfer switch under a load condition the switch will
transfer to generator emergency power. When testing or exercising the transfer switch
under a no load condition the switch will not transfer and stay in the normal power
position. Please refer to the TSC3A user manual for a more advanced and detailed
outlook on the TSC3A and its functionality.
User Manual for the OPT2600 Series Automatic Transfer Switch

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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, next to the 8 pin octal socket, is in
the ON position (position away from the octal socket), 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, located on the relay module, next to the 8 pin octal socket, is in
the OFF position (position closest to the octal socket), the on board relay coil is bypassed,
and voltage sensing is provide by an optional 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 causing a utility source failure. The adjustable voltage-sensing
module recommended for use with the OPT2600-2 Automatic Transfer Switch is the
Symcom 201-200-SP-T Rev5.20. The adjustable voltage-sensing module recommended
for use with the OPT2600-3 Automatic Transfer Switch is the Symcom 201A.
ADJUSTMENT PROCEDURE
Rotate the line voltage adjustment to the nominal line voltage feeding the transfer switch.
The nominal line voltage can be measured between phase A and phase C of the line side
inputs on the normal breaker. 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.
Please note that there will be a 3 second delay between emergency to normal transfer.
This can be observed be a flashing LED on the monitor.
User Manual for the OPT2600 Series Automatic Transfer Switch

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1:2:2 System Operation:
WARNING: THE RELAY BOARD IS FACTORY SET FOR 12VDC
APPLICATIONS. IF INSTALLING IN A 24VDC
SYSTEM, TWO JUMPERS NEED TO BE CUT.
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
2: INSTALLATION INFORMATION
2:1 General
The basic OPT2600 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.
2:2 Recommended Upstream Protection
When protected by a circuit breaker rated 600A maximum. This switch is suitable for use
on a circuit capable of delivering not more than:
65,000A RMS SYMMETRICAL AT 240V
35,000A RMS SYMMETRICAL AT 480V
25,000A RMS SYMMETRICAL AT 600V
When protected by a class J, T or R fuse rated 600A maximum. This switch is suitable
for use on a circuit capable of delivering not more than:
100,000A RMS SYMMETRICAL AT 240V
100,000A RMS SYMMETRICAL AT 480V
May open circuit above 4,000A
Use copper or aluminum wiring at a minimum 75C rating for power terminals.
User Manual for the OPT2600 Series Automatic Transfer Switch

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All electrical wiring connections have a recommended tightening torque. The following
chart shows the required electrical tightening torque to allow safe operation.
Wiring Connections
aluminum/copper
Connector Mounting
Screws
300 IN-LBS 132 IN-LBS
Wire size range 3/0 to 500MCM copper and 4/0 to 500MM aluminum.
2:3 Open Type Transfer Switches:
Open type options allow transfer switches to be shipped with no enclosures. All open
type UL approved transfer switch will be required to be placed in a minimum size
enclosure to allow proper spacing between electrical components and the enclosure wall.
The following chart shows the minimum required dimensions to allow the safe operation
of these Switches.
Transfer Switch
Amperage Rating
Enclosure
Dimensions
(Height x Width x Diameter)
600A 60 x 30 x 10
The transfer switch must be in accordance with the following requirements:
For models OPT2600-2-120/240V and OPT2600-3-208/240V
1. The minimum spacing requirements per UL-1008 must not be less than 1/4”
through air and 3/8" over the surface of the insulating material. These measures
must exist between any uninsulated live part and another uninsulated live part of
opposite polarity, uninsulated grounded part other tan the enclosure or any
exposed metal part.
2. Not less than 1/2" measured over the shortest distance between any uninsulated
live parts and the walls of the metal enclosure, including fittings for conduit or
armored cable.
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For models OPT2600-3-480V and OPT2600-3-600V
1. The minimum spacing requirements per UL-1008 must not be less than 3/8”
through air and 1/2" over the surface of the insulating material. These measures
must exist between any uninsulated live part and another uninsulated live part of
opposite polarity, uninsulated grounded part other tan the enclosure or any
exposed metal part.
2. Not less than 1/2" measured over the shortest distance between any uninsulated
live parts and the walls of the metal enclosure, including fittings for conduit or
armored cable.
2:4 Remote test switch installation:
An optional test switch may be installed which allows remote testing of the transfer
switch. The purpose of the test switch is to simulate a utility power failure. The remote
test switch would be connected between the test + and test - location on the terminal
block. When the test + and test- contacts on the terminal block are closed, a relay
energizes simulating a utility power failure. A test switch rated at a minimum of 1A
should be used.
.
3: REPLACING PARTS
WARNING: When replacing any parts of the mechanism, isolate the
transfer switch from all possible sources of power.
The OPT2600 transfer switch mechanism has been designed to allow all components to
be accessible and readily removable from the front of the back panel.
Replacement parts should be identified with reference to the Parts List on page 10 and the
Assembly Drawing on page 15. All parts are available direct from the factory. Be sure to
state the model and serial number of the switch.
User Manual for the OPT2600 Series Automatic Transfer Switch

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3:1 REPLACEMENT PARTS LIST
PARTS DESCRIPTION Ref. PARTS DESCRIPTION Ref.
No. No.
Inner Panel 1 Washer 1/2 “ flat 39
Molded Case Switch 2 Washer 1/2“ spring lock 40
Screw 1/4”- 20x3” round HD phillips 3 Nut 1/2“–20 Jam 41
Washer 1/4" spring lock 4 Screw 1/2“-20x 1 1/2” 42
Top Support 5 Bus bar assembly 43
Screw 10-24x1/2" pan head phillips 6 Screw 5/16"-18x1" 44
Washer #10 spring lock 7 Washer 5/16“ spring lock 45
Washer #10 flat 8 Connector lug 46
Gear Motor 9 Neutral block 47
Screw 10-32x1/2" pan HD 10 Screw 1/4-20 x 5/8" 48
Crank 11 Washer 1/4“ flat 49
Screw 1/4“-28x1/4” set 12 Insulator 50
Cam 13 Screw 1/4“-20 x 1/2" 51
Screw #6-32 x 1/2" flat HD 14 Limit switch spacer 52
Washer #6 Spring Lock 15 Nylon pad 53
Washer #6 flat 16 Limit switch insulator 54
Limit Switch Support 17 Nylon spacer (hand knob) 55
Screw #6-32x1/4" 18 Screw #10-32 x 1/2" flat HD 56
Limit Switch 19
Screw #4-40x5/8" 20
Washer #4 Spring Lock 21
Washer #4 flat 22
Actuator Carrier 23
Guide rod 24
Washer shoulder 25
Springrip Fastener 26
Spacer Nylon 27
Screw #10-32x1" 28
Nut #10-32 Hex 29
Pivot support 30
Arm 31
Washer Nylon 32
Spacer Nylon 33
Washer 5/16“ flat 34
Nut 5/16-18 hex self locking 35
Screw 5/16“-24x1” 36
Hand Knob 37
Spacer Nylon 38
User Manual for the OPT2600 Series Automatic Transfer Switch

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3:1 MAIN SWITCH REMOVAL AND REPLACEMENT
WARNING: When replacing any parts of the mechanism, isolate the
transfer switch from all possible sources of power.
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) Disconnect wiring to limit switches and motor and any tie-points on the top
support.
c) The top support complete with motor and operating mechanism can now be
lifted clear after removing the eight top support screws (see mechanical
assembly on page 14).
d) After removing the buss bar from the breakers, 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 actuators equally straddle the switch
operating levers. Please note that the roller assemblies may need to be
independently adjusted when replacing breakers. The roller adjustments
may be performed as follows:
1. To give maximum travel of the lever arm, position the crank block at a
90-degree angle in relation to the arm.
2. Using the breaker which is in the OFF position, push the white roller
tight against the breaker lever. Securing the #10 screw (mechanical
assembly reference # 28) with a screw driver, tighten the two #10 hex
nuts (mechanical assembly reference # 29) closest to the roller against
the actuator carrier bracket.
3. Confirming that the roller is tight against the switch lever, tighten the
two #10 hex nuts farthest from the roller tight against the actuator
carrier bracket
4. Manually transfer the switch to the opposite position. Repeat steps 1, 2
and 3 above.
5. Check adjustments and repeat if necessary.
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3:2 MOTOR REMOVAL AND REPLACEMENT
WARNING: When replacing any parts of the mechanism, isolate the
transfer switch from all possible sources of power.
– Electrically isolate the transfer switch from all power sources.
– Remove the top support as in section 3:1 steps a, b and c above .
– Loosen the set screw holding the crank to the motor shaft.
– Remove six screws securing the motor to the underside of the top support
bracket (see mechanical assembly on page 14). The motor can now be
removed.
Replacement is the reverse of the above procedure.
4: MANUAL TRANSFER OF MECHANISM
WARNING: When performing a manual transfer of mechanism, isolate
the transfer switch from all possible sources of power.
PRECAUTION HAS TO BE TAKEN WHEN PERFORMING THIS TRANSFER:
THE TRANSFER SWITCH MUST BE ISOLATED FROM ALL POSSIBLE
SOURCES OF POWER.
The OPT2600 includes the suitable sensing circuitry for automatically transfer 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. If for any reason the switch fails to transfer
when the normal power supply fails, the user may manually transfer the switch by using
the knob on the lever arm. Please confirm that the transfer switch is isolated from all
power sources before manually transferring from the normal to emergency position.
Significant force must be supplied to the lever arm knob to perform the transfer. When
performing a mechanical transfer both breakers must be properly activated, this can be
achieved by the presence of two clicks that will confirm a successful transfer. If the
switch fails to transfer back to the normal position when the utility power is restored,
manually transfer back to normal supply using the precautions described above. Confirm
the proper shut down of the generator or manually shut down if required. The switch
should only need to be transferred manually in the event of a failure within the OPT2600
controls. Please call technical support if any transfer failures are observed.
User Manual for the OPT2600 Series Automatic Transfer Switch

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5: RECOMMENDED MAINTENANCE
WARNING: When performing any maintenance of the mechanism,
isolate the transfer switch from all possible sources of
power.
The OPT2600 transfer switch assembly has been designed to require minimum attention
under all environmental conditions normally encountered. All sliding and bearing
surfaces have a thin coating of grease applied at the factory. This thin coating minimizes
accumulation of dust and grit at these locations. The gear-motor is also lubricated for the
life of the unit, and requires no attention.
Periodically inspect 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.
All transfer switch parts are made of corrosion resistant material or is plated, coated or
painted for corrosion protection.
User Manual for the OPT2600 Series Automatic Transfer Switch

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6:1 OPT2600 MECHANICAL ASSEMBLY
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6:2 OPT2600 GENERAL ARRANGEMENT
User Manual for the OPT2600 Series Automatic Transfer Switch

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6:3 OPT2600-2-120/240V WIRING DIAGRAM
User Manual for the OPT2600 Series Automatic Transfer Switch

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6:4 OPT2600-3-208/240 WIRING DIAGRAM
User Manual for the OPT2600 Series Automatic Transfer Switch

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6:5 OPT2600-3-480 WIRING DIAGRAM
User Manual for the OPT2600 Series Automatic Transfer Switch

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6:6 OPT2600-3-600 WIRING DIAGRAM
User Manual for the OPT2600 Series Automatic Transfer Switch

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7: ENGINE EXERCISER
Introduction
The functions of the exerciser time clock are shown in the diagram below. The time
clock has two slide switches with three positions: The switch in the upper right corner is a
SET SWITCH used to set the present time and day for your locality, run the 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 time clock
erasing any previous program.
User Manual for the OPT2600 Series Automatic Transfer Switch