Marathon TSC 900 Service Manual

TSC 900

TRANSFER SWITCH CONTROLLER

INSTALLATION, OPERATING &

Part ID 013190 PM0151 REV 1 15/10/08

9087A – 198th Street, Langley, BC Canada V1M 3B1  Telephone (604) 888-0110

Telefax (604) 888-3381  E-Mail: info@thomsonps.com  www.thomsonps.com

SERVICE MANUAL

9087A – 198th Street, Langley, BC Canada V1M 3B1  Telephone (604) 888-0110

Telefax (604) 888-3381  E-Mail: info@thomsonps.com  www.thomsonps.com

TSC 900 TRANSFER SWITCH CONTROLLER

TABLE OF CONTENTS

1. INTRODUCTION 1

1.1. PRODUCT REVISION HISTORY 1

1.2. GENERAL DESCRIPTION 1

2. INSTALLATION 2

2.1. GENERAL INFORMATION 2

2.2. NOTES TO INSTALLER 3

2.3. AC VOLTAGE SENSING INPUT 4

2.4. AC CURRENT SENSING INPUT 4

2.5. AC CONTROL POWER INPUT 5

2.6. AUXILIARY DC CONTROL POWER INPUT 5

2.7. PROGRAMMABLE INPUTS 5

2.8. OUTPUTS 5

2.9. EXTERNAL ATS CONTROL WIRING 5

2.10. REMOTE START CONTACT FIELD WIRING 6

2.11. COMMUNICATION CABLE INSTALLATION 6

2.12. DIELECTRIC TESTING 7

3. DESCRIPTION 8

3.1. GRAPHICAL HMI CONTROLLER (GHC) DISPLAY HARDWARE 9

3.2. SWITCH CONTROL UNIT (SCU) HARDWARE 10

3.3. ATS OPERATION MODE DESCRIPTIONS 12

3.4. AUTOMATIC SEQUENCE OF OPERATION 14

3.4.1. OPEN TRANSITION TRANSFER 14

3.4.2. CLOSED TRANSITION TRANSFER 15

3.4.3. AUTOMATIC LOAD SHED OPERATION 17

3.4.4. TEST MODE 18

3.4.5. ABNORMAL SEQUENCE OF OPERATION 19

3.5. GHC DISPLAY MAIN MENU PAGE DESCRIPTIONS 20

3.5.1. HOME PAGE 21

3.5.2. UTILITY METERING PAGE 22

3.5.3. GENERATOR METERING PAGE 22

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TSC 900 TRANSFER SWITCH CONTROLLER

3.5.4. LOAD METERING PAGE 23

3.5.5. ALARMS PAGE 24

3.5.6. ALARMS LOG PAGE 25

3.5.7. EVENTS LOG PAGE 25

3.5.8. SYNC PAGE 26

3.5.9. SCHEDULER PAGE 27

3.5.10. SETTINGS PAGE 27

3.5.11. SYSTEM PAGE 28

3.6. GHC DISPLAY SYSTEM SUBMENU PAGE DESCRIPTIONS 29

3.6.1. IMPORT/EXPORT DATABASE 29

3.6.2. TIME/DATE SETUP 29

3.6.3. MANAGE USERS 30

3.6.4. SYSTEM INFORMATION 30

3.6.5. INPUT MAPPING 31

3.6.6. OUTPUT MAPPING 31

3.6.7. LOGS 32

3.6.8. COM STATUS 32

4. OPERATING INSTRUCTIONS 33

4.1. GHC SCREEN PAGE NAVIGATION 33

4.2. ON LOAD TEST INSTRUCTIONS (UTILITY POWER FAIL SIMULATION) 34

4.3. OFF LOAD TEST INSTRUCTIONS (GENERATOR NO LOAD TEST) 35

4.4. TIMED TEST INSTRUCTION 36

4.5. OPEN/CLOSED TRANSITION TRANSFER OPERATION 37

4.5.1. OPEN TRANSITION IN-SYNC TRANSFER OPERATION (MODEL X) 38

4.5.2. CLOSED TRANSITION OPERATION (MODEL 3 & 4) 38

4.6. TRANSFER FAIL ALARM RESET 39

4.7. TIMER BYPASS 40

4.8. MANUAL UTILITY RETRANSFER CONTROL 41

4.9. SERVICE DISCONNECT MODE 41

4.10. PHASE UNBALANCE PROTECTION ALARM RESET 42

4.11. TRANSFER HALTED ALARM RESET 43

5. PROGRAMMING INSTRUCTIONS 44

5.1. PASSWORD SECURITY DESCRIPTION (USERS ADMIN) 44

5.2. USER LOGIN PROCEDURE 45

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TSC 900 TRANSFER SWITCH CONTROLLER

5.3. ADMINISTRATOR PASSWORD MANAGEMENT PROCEDURE 46

5.4. SYSTEM TIME/DATE ADJUSTMENT 47

5.5. VOLTAGE CHANGE PROCEDURE 48

5.6. EXERCISE TIMER SETUP 49

5.6.1. ADDING NEW EXERCISE SCHEDULE EVENT 50

5.6.2. EDITING EXISTING EXERCISE SCHEDULE EVENT 50

5.7. PROGRAMMABLE INPUT MAPPING 51

5.8. PROGRAMMABLE OUTPUT MAPPING 54

5.9. SYSTEM SETTINGS 58

5.9.1. SYSTEM PHASES 58

5.9.2. SYSTEM VOLTAGE 58

5.9.3. SYSTEM FREQUENCY 58

5.9.4. PHASE ROTATION REVERSED 58

5.9.5. RATED GENERATOR POWER 59

5.9.6. CT RATIO (CURRENT TRANSFORMER) 59

5.9.7. PT RATIO (POTENTIAL TRANSFORMER) 59

5.9.8. LOAD NAME 59

5.9.9. SOURCE 1 (UTILITY) NAME 59

5.9.10. SOURCE 2 (GEN) NAME 59

5.9.11. APPLICATION MODEL 59

5.9.12. SWITCH OPERATION 59

5.9.13. SWITCH MODEL 60

5.9.14. TRANSFER SWITCH MECHANISM OPERATION TIME 60

5.10. OPTION SETTINGS 60

5.10.1. CURRENT METERING 60

5.10.2. GEN (SOURCE 2) COMMIT TO TRANSFER 60

5.10.3. ENABLE LOAD SHED ON UNDER FREQUENCY 60

5.10.4. ENABLE LOAD SHED ON OVER POWER 61

5.10.5. HALT OPERATION ON REVERSED SOURCE 61

5.10.6. ENABLE FAIL TO UNLOAD ALARM (CTTS MODEL 4) 61

5.10.7. TRIP UTILITY (SRC 1) WHEN CLOSED TRANSITION INHIBIT ACTIVATED 61

5.10.8. HALT TRANSFER ON FAIL TO EXTERNAL SYNC CHECK 61

5.10.9. MANUAL UTILITY RETRANSFER CONTROL 62

5.10.10. FORCE TRANSFER 62

5.10.11. GHC SLEEP MODE TIMEOUT 63

5.10.12. LOAD POWER METERING 63

5.10.13. MODBUS RTU 63

5.10.14. MODBUS TCP/IP 63

5.10.15. ENABLE SECURITY BYPASS 63

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TSC 900 TRANSFER SWITCH CONTROLLER

5.10.16. FAIL TO AUTO SYNC ALARM 63

5.10.17. OPEN TRANSITION IN-SYNC TRANSFER (ATS MODEL X) 64

5.10.18. CLOSED TRANSITION TRANSFER (CTTS MODEL 3 & 4) 64

5.10.19. NEUTRAL DELAY BYPASS 64

5.10.20. REVERT TO OPEN TRANSITION 65

5.10.21. ENABLE TRANSFERS TO UTILITY 65

5.10.22. ENABLE TRANSFERS TO GENERATOR 65

5.10.23. EXTENDED PARALLEL TRANSFER (CTTS MODEL 4) 66

5.11. DELAY SETTINGS 67

5.11.1. UTILITY RETURN DELAY 67

5.11.2. GEN COOL DOWN DELAY 67

5.11.3. GEN START DELAY 67

5.11.4. GEN WARM UP DELAY 67

5.11.5. GEN COMMIT TO TRANSFER DELAY 67

5.11.6. DEPART DELAY 67

5.11.7. TRANSFER FAIL DELAY 68

5.11.8. TRANSFER MAX ERROR CONDITION DELAY 68

5.11.9. TIMER GUARD DELAY 68

5.11.10. TRANSFER FIND NEUTRAL DELAY 68

5.11.11. TRANSFER NEUTRAL DELAY 68

5.11.12. TRANSFER PRE DELAY (LDC) 68

5.11.13. TRANSFER POST DELAY (LDC) 69

5.11.14. DISCONNECTION RESUME TIME 69

5.11.15. LOAD SHED INITIATE DELAY 69

5.11.16. LOAD SHED UNSHED DELAY 69

5.11.17. TRIP RETRY ON/OFF PULSE TIME (SRC1&2) 69

5.11.18. TRIP RETRY DURATION TIMER (SRC1&2) 70

5.11.19. CLOSE RETRY ON/OFF PULSE TIME (SRC1&2) 70

5.11.20. CLOSE RETRY DURATION TIMER (SRC1&2) 70

5.12. UTILITY/GEN SET POINTS (VOLTAGE/FREQUENCY) 71

5.12.1. UNDER VOLTAGE DELAY (DROPOUT) 71

5.12.2. UNDER VOLTAGE DROPOUT 71

5.12.3. UNDER VOLTAGE PICKUP 71

5.12.4. OVER VOLTAGE DELAY (PICKUP) 71

5.12.5. OVER VOLTAGE DROPOUT 71

5.12.6. OVER VOLTAGE PICKUP 72

5.12.7. UNBALANCED VOLTAGE LATCH 72

5.12.8. PHASE UNBALANCE DELAY (PICKUP) 72

5.12.9. PHASE UNBALANCE DROP OUT 72

5.12.10. PHASE UNBALANCE PICK UP 72

5.12.11. UNDER FREQUENCY DELAY (DROPOUT) 72

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TSC 900 TRANSFER SWITCH CONTROLLER

5.12.12. UNDER FREQUENCY DROPOUT 73

5.12.13. UNDER FREQUENCY PICKUP 73

5.12.14. OVER FREQUENCY DELAY (PICKUP) 73

5.12.15. OVER FREQUENCY DROPOUT 73

5.12.16. OVER FREQUENCY PICKUP 73

5.12.17. SOURCE VOLTAGE BLACKOUT DELAY (DROPOUT) 73

5.12.18. SOURCE VOLTAGE BLACKOUT DROPOUT 73

5.12.19. SOURCE VOLTAGE BLACKOUT PICKUP 74

5.12.20. PHASE REVERSAL DELAY (PICKUP) 74

5.12.21. PHASE REVERSAL DROP OUT 74

5.12.22. PHASE REVERSAL PICK UP 74

5.12.23. GEN MUST START DELAY 74

5.13. LOAD VOLTAGE SET POINTS 74

5.13.1. LOAD VOLTAGE BLACKOUT DELAY (DROPOUT) 75

5.13.2. LOAD VOLTAGE BLACKOUT DROPOUT 75

5.13.3. LOAD VOLTAGE BLACKOUT PICKUP 75

5.14. LOAD SHED SET FREQUENCY & POWER POINTS 75

5.14.1. LOAD SHED POWER (kW) DELAY (PICKUP) 76

5.14.2. LOAD SHED POWER (kW) DROP OUT 76

5.14.3. LOAD SHED POWER (kW) PICK UP 76

5.14.4. LOAD SHED FREQUENCY PICK UP 76

5.14.5. LOAD SHED FREQUENCY DROP OUT 76

5.15. IN-SYNC TRANSFER SET POINTS 76

5.15.1. CLOSED TRANSITION MAX OVERLAP TIMER 76

5.15.2. IN-SYNC WAIT DELAY 77

5.15.3. EXTERNAL SYNC CHECK WAIT DELAY 77

5.15.4. SOURCE FREQUENCY DIFFERENTIAL HIGHER THRESHOLD 77

5.15.5. SOURCE FREQUENCY DIFFERENTIAL LOWER THRESHOLD 77

5.15.6. SOURCE VOLTAGE DIFFERENTIAL HIGHER THRESHOLD 77

5.15.7. SOURCE VOLTAGE DIFFERENTIAL LOWER THRESHOLD 77

5.15.8. FAIL TO UNLOAD TIMER (CTTS MODEL 4) 78

6. FACTORY DEFAULT PROGRAMMING 79

7. TSC 900 TYPICAL CONNECTION DIAGRAM 80

8. TSC 900 WIRING PIN CONNECTIONS 81

9. TROUBLESHOOTING 82

10. REPLACEMENT PARTS 85

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TSC 900 TRANSFER SWITCH CONTROLLER

11. PRODUCT RETURN POLICY 86

12. NOTES 87

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1. INTRODUCTION

621, 15/04/07

Original Release

867, 15/10/03

Add Closed Transition Transfer Capability, Misc Feature Enhancements & Bug Fixes

1.0.0.0 15/04/07

Original Release

1.1.0.xxxxx 15/10/03

Add Closed Transition Transfer Capability, Misc Feature Enhancements & Bug Fixes

Rev 0 15/04/07

Original release

Rev 1 15/10/08

Add Closed Transition Transfer Capability, Misc Feature Enhancements & Bug Fixes

1.1. PRODUCT REVISION HISTORY

The following information provides an historical summary of changes made to this product since the original release.

SCU Firmware Version

GHC Firmware Version

Operating & Service Manual Version

TSC 900 TRANSFER SWITCH CONTROLLER

Related Product Instruction Manuals

 TSC 900 ModbusTM Communication, PM152  TS 870 Instruction Manual, PM062  TS 870 Quick Start Manual, PM150  TS 880 Instruction Manual, PM064

Contact Thomson Power Systems, to obtain these instruction manuals. A soft-copy of the most current versions of these manuals are available at www.thomsonps.com.

1.2. GENERAL DESCRIPTION

The TSC 900 controller utilizes multiple 32 bit microprocessor-based design technology, which provides high accuracy for all voltage sensing and timing functions. Digital Signal Processing (DSP) technology is utilized for all voltage, frequency and current sensing. The TSC 900 is factory configured to control all the operational functions and display features of the automatic transfer switch. All features of the TSC 900 are fully programmable from the front panel color graphical touchscreen display and are security password protected. The graphical touchscreen display screen provides a user-friendly operator interface with many display options available. The microprocessor design provides many integrated standard features, which were previously only available as add-on optional features.

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2. INSTALLATION

This equipment contains static-sensitive parts. Please observe the following

anti-static precautions at all times when handling this equipment. Failure to

observe these precautions may cause equipment failure and/or damage.

TSC 900 TRANSFER SWITCH CONTROLLER

CAUTION!!!

The following precautions must be observed:  Discharge body static charge before handling the equipment (maintain exposed body contact

with a properly grounded surface while handling the equipment, a grounding wrist strap can/should also be utilized).

 Do not touch any components on the printed circuit board with your hands or any other

conductive equipment.

 Do not place the equipment on or near materials such as Styrofoam, plastic and vinyl. Place

the equipment on properly grounded surfaces and only use an anti-static bag for transporting the equipment.

2.1. GENERAL INFORMATION

NOTE:

Installations should be done in accordance

The following installation guidelines are provided for general information only pertaining to typical site installations. For specific site installation information, consult Thomson Power Systems as required. NOTE: Factory installations of THOMSON POWER SYSTEMS

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with all applicable electrical regulation codes as required.

TSC 900 TRANSFER SWITCH CONTROLLER

supplied transfer switches that have been tested and proven may deviate from these recommendations.

2.2. NOTES TO INSTALLER

If the transfer switch has programmable/multi-tap system voltage capability (refer to electrical schematic), confirm the transfer switch has been configured for the system voltage.

WARNING

Failure to confirm and match transfer

switch voltage with the system voltage

could cause serious equipment damage.

If the transfer switch requires reconfiguring, the TSC 900 controller will also require reprogramming.

CAUTION!!!

Qualified personnel must complete all installation and/or service work performed

only. Failure to do so may cause personal injury or death.

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TSC 900 TRANSFER SWITCH CONTROLLER

2.3. AC VOLTAGE SENSING INPUT

The TSC 900 can accept direct AC voltage sensing inputs on the generator, utility and load from 120-600VAC (nominal). Sources up to 600VAC (phase to phase) and can connected wye or delta with grounded or ungrounded neutral without the need for additional sensing transformers. The TSC 900 voltage sensing can support the following types of electrical systems:

2.4. AC CURRENT SENSING INPUT

The TSC 900 can accept 4 x 0-5Aac current inputs from the secondary windings of current transformers (CT’s). CT’s are to be connected on the load side of the ATS (Phase A,B,C & N). Wiring of CT primary and secondary windings must be done in strict accordance with schematic diagram to ensure the correct phasing on 3 phase systems.

Do not unplug any current transformer inputs while

energized as severe high voltages can develop which may

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WARNING

cause personal injury or death.

TSC 900 TRANSFER SWITCH CONTROLLER

Engine Start Contacts

Qty 2

Isolated Form B contacts (10A, 250VAC Resistive)

Programmable Output Contacts

Qty 8

Isolated Form C contacts (2A, 250VAC Resistive)

Close to Utility Supply

Qty 1

120VAC1, 10A (Resistive) powered output contact

Close to Generator Supply

Qty 1

120VAC1, 10A (Resistive) powered output contact

Trip Utility Supply

Qty 1

120VAC1, 10A (Resistive) powered output contact

Trip Generator Supply

Qty 1

120VAC1, 10A (Resistive) powered output contact

2.5. AC CONTROL POWER INPUT

The TSC 900 requires 120VAC (nominal) control power input voltage. Independent AC control power is required from both utility and generator supplies via potential transformers. AC control power is utilized for internal TSC 900 control circuits and external control device loads. The TSC 900 requires approximately 12VA AC power for internal control circuits. The maximum external load is limited by output contact ratings (i.e. 10A resistive, 120/250VAC). Total AC control power requirements for each supply must be determined by adding both internal and external load requirements.

2.6. AUXILIARY DC CONTROL POWER INPUT

The TSC 900 can be optionally supplied with 24Vdc auxiliary control power input voltage for applications requiring continuously energized control and display features. The maximum input power draw is 20Watts. The 24Vdc power must be from a regulated/filtered DC supply with maximum +-10% voltage range.

2.7. PROGRAMMABLE INPUTS

The TSC 900 provides Qty 16 Programmable Inputs. Each input is activated by external contact closure to common (i.e. DC Negative ground). Each programmable input can be independently programmed to different functions. Refer to Programming section for available features.

2.8. OUTPUTS

The TSC 900 provides the following types of output circuits:

NOTE: Output voltage is dependent upon AC control power input voltage.

Interposing relays are required between the TSC 900 outputs and the end device if loads exceed the output current rating.

2.9. EXTERNAL ATS CONTROL WIRING

As a minimum, all external control wiring to/from the ATS must conform to the local regulatory authority having jurisdiction on electrical installations. Specific wire sizes listed below are for typical circuits of distances up to 500ft (150m)1, are as follows:

Utility or Generator Voltage Sensing #14 AWG (2.5mm2)

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TSC 900 TRANSFER SWITCH CONTROLLER

Transfer output signals #14 AWG (2.5mm2) Remote Start Contact for Engine Controls #14 AWG (2.5mm2) NOTE: For long control wire runs or noisy electrical environments the control wires

should be twisted & shielded with a suitable drain wire. The shielded cable drain wire must be grounded at one end only. The drain wire grounding location may vary as micro-processor controllers generally exist at both ends (engine generator set & transfer switch) and one may be more susceptible depending on the level of induced noise. The most susceptible controller will require the shield ground point as close as possible to the controller. Wire runs from 500ft to 1000ft should be twisted and shielded and increased to #12 AWG where total loop resistance is greater than 5 ohms.

For distances exceeding 1000ft. (300m) consult Thomson Power Systems

2.10. REMOTE START CONTACT FIELD WIRING

Field wiring of a remote start contact from a transfer switch to a control panel should conform to the following guidelines to avoid possible controller malfunction and/or damage.

2.8.1. Remote start contact wires (2 #14 AWG (2.5mm2)) should be run in a separate conduit (ferromagnetic type) and in all cases separated from any AC wiring.

2.8.2. Avoid wiring near AC power cables to prevent pick-up of induced voltages.

2.8.3. An interposing relay may be required if field-wiring distance is excessively long (i.e. greater than 1000 feet (300m)) and/or if a remote contact has a resistance of greater than 5.0 ohms. In extremely noisy environments, the wire run lengths indicated may not provide reliable operation and can only be corrected by the use of an interposing relay. The interposing relay is generally installed at the engine controls and utilizes DC power. It is strongly suggested that the ground return wire of the interposing relay be used for the interface to the TSC 900 remote start contact, this will ensure integrity of the DC power supply to the engine generator set controls in the event of a shorted or grounded wire remote start interface wire.

2.8.4. The remote start contact provided is voltage free (i.e. dry contact). Exposing the remote start contact to voltage or current levels in excess of its rating will damage the transfer controller.

2.11. COMMUNICATION CABLE INSTALLATION

Communication cable wiring from the controller’s communication port must be suitably routed to protect it from sources of electrical interference. Guidelines for protection against possible electrical interference are as follows:

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TSC 900 TRANSFER SWITCH CONTROLLER

 Use high quality, shielded cable only with drain wire grounded at the controller end

only.

 Route the communication cable at least 3 M (10’) away from sources of electrical

noise such as variable speed motor drives, high voltage power conductors, UPS systems, transformers, rectifiers etc.

 Use separate, dedicated conduit runs for all communication cables. Do not tightly

bundle communication cables together in the conduit. Conduit should be ferromagnetic type near sources of possible electrical interference. The entire length of conduit should be grounded to building earth ground.

 When communication cables must cross over low or high voltage AC power

conductors, the communication cables must cross at right angles and not in parallel with the conductors.

For additional information on protection against electrical interference, contact THOMSON POWER SYSTEMS factory.

2.12. DIELECTRIC TESTING

Do not perform any high voltage dielectric testing on the transfer switch with the TSC 900 controller connected into the circuit, as serious damage will occur to the controller. All AC control fuses or control/sensing circuit isolation plugs connected to the TSC 900 must be removed/disconnected if high voltage dielectric testing is performed on the transfer switch.

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TSC 900 TRANSFER SWITCH CONTROLLER

USB 2.0 Cable

GHC

SCU

3. DESCRIPTION

The TSC 900 controller consists of two parts; a front door mounted graphical touch screen display (GHC), and a switch control unit (SCU) which is mounted inside the transfer switch door. The two parts are interconnected via a USB 2.0 high speed communication cable which includes DC power.

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TSC 900 TRANSFER SWITCH CONTROLLER

1 2 3 4 5 6 7

3.1. GRAPHICAL HMI CONTROLLER (GHC) DISPLAY HARDWARE

The GHC Display is shown as in FIGURE 7. The GHC is interconnected to the SCU via plug-in USB cable. The main features of the GHC Display are described as follows with reference to FIGURE 7.

FIGURE# 7

1. RS232 Communication Port #1: This port is utilized for Modbus RTU Serial communication

2. RS232 Communication Port #2: This port is utilized RS232 Serial communication

3. USB Communication Port #1: This port is utilized for communication from GHC to TSC 900 SCU module.

4. Ethernet Communication Port: This port is utilized for Modbus TCP Ethernet communication

5. USB Communication Port #2: This port is utilized for customer use.

6. USB Communication Port #3: This port is utilized for customer use.

7. SD Memory Card Slot: This is used for program operation and memory storage

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TSC 900 TRANSFER SWITCH CONTROLLER

2 1 4 3 5 8 7

16 6 10

3.2. SWITCH CONTROL UNIT (SCU) HARDWARE

The Switch Control Unit internal PCB is shown in the following diagram:

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TSC 900 TRANSFER SWITCH CONTROLLER

1 2 3

4 5 16

The Switch Control Unit (SCU) with case and main I/O connections are detailed in the following diagram:

1. J9 – 24Vdc Auxiliary Control Power

2. J2 – Utility Voltage Sensing (PH A,B,C,N)

3. J3 – Generator Voltage Sensing (PH A,B,C,N)

4. J4 – Load Voltage Sensing (PH A,B,C,N)

5. J5,6,7,8 – Load Current Sensing (PH A,B,C,N)

6. J21 –SCU SD Memory Card (Card Located inside case-not shown)

7. J11a Programmable Output Contacts #1-4

8. J11b Programmable Output Contacts #5-8

9. J12a Programmable Inputs #1-8

10. J12b Programmable Inputs #9-16

11. J10a Engine Start 2 Contact (Single Gen SRC 2)

12. J10b Engine Start 1 Contact (Dual Gen SRC 1)

13. J13 – GHC Aux 5Vdc Power

14. J14- GHC USB Port

15. J15 – RS232 Programming Port

16. J1 – ATS Control

17. SCU Healthy Diagnostic LED

18. Engine Start Outputs On Diagnostic LED

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TSC 900 TRANSFER SWITCH CONTROLLER

Mode

Description

ATS Mechanism Control Outputs

Engine Start Output

AUTO

ATS automatically transfers to generator (source 2) during a utility (source 1) failure and automatically returns power to utility once restored

Outputs automatically operate ATS mechanism per automatic sequence of operation

Output contact closes to start engine during a utility (source 1) failure and opens to stop engine once utility power has transferred back on load.

OFF

ATS is Out of Service - will not automatically operate during a utility power failure

Outputs remain in their last state to keep ATS in its current position

Output is disabled - engine will not start during a utility power failure1

MANUAL

ATS is Out of Service -will not automatically operate during a utility power failure. ATS can be operated manually for testing or emergency operation

Outputs de-energize to allow ATS to be operated manually

Output is disabled - engine will not start during a utility power failure1 .Engine will stop if was previously running

SERVICE DISCONNECT

ATS transfers to neutral position to disconnect power to the load. ATS will not automatically operate during a utility power failure.

Outputs momentarily energize to move ATS mechanism to the neutral position

Output is disabled - engine will not start during a utility power failure1.Engine will stop if was previously running

ON LOAD TEST

When ONLOAD TEST mode is initiated, a utility power failure condition will be simulated which will cause engine to start and ATS will transfer to generator supply. When TEST mode is terminated, ATS will transfer back to utility supply and engine will stop

Outputs automatically operate ATS mechanism per automatic sequence of operation

Output contact closes to start engine during the ONLOAD TEST mode. Output automatically opens when test mode is terminated and ATS is back on utility power

OFF LOAD TEST

When OFF LOAD TEST mode is initiated, engine will start and run off load. When OFF LOAD TEST mode is terminated, engine will stop

Outputs do not change state unless utility or generator supply fails in Off Load test mode

Output automatically closes to start engine during the OFF LOAD test mode. Output automatically opens when test mode is terminated

TIMED TEST

When a TIMED TEST is initiated, the ATS will perform test per the selected type (i.e. on load or off load) and time period. The Generator, will continue to run for the TIMED TEST duration, then will automatically stop.

Outputs operate ATS mechanism per automatic sequence of operation if programmed for ON LOAD TEST operation.

Output contact closes to start engine during the TIMED TEST mode. Output automatically opens when exercise mode is terminated

EXERCISE SCHEDULE

When an EXERCISE SCHEDULE occurs, the ATS will perform exercise test on the preselected calendar date and time. The Generator will operate on load or off load as selected, and will continue to run for the Exercise duration period as selected. If a reoccurring Exercise mode is selected, ATS will repeat an exercise test based on the calendar dates and times as selected.

Outputs operate ATS mechanism per automatic sequence of operation if programmed for ON LOAD TEST operation.

Output contact closes to start engine during the EXERCISE test mode. Output automatically opens when exercise mode is terminated

3.3. ATS OPERATION MODE DESCRIPTIONS

The TSC 900 has the following main operating modes as described per the table below:

The TSC 900 requires continuous control power (i.e. utility/gen power on, or 24Vdc aux power on) to keep the automatic engine

start output disabled. If control power is de-energized, the engine start output will energize in approximately 3 minutes, once its internal control power reservoir de-energizes. This in turn will cause a repeating engine start/stop event every 3-4 minutes. To prevent engine start/stop cycling condition upon loss of control power, the local engine control panel should be selected for the OFF operating mode.

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TSC 900 TRANSFER SWITCH CONTROLLER

Operating modes for the ATS are selected either via the TSC 900 GHC Home page screen (using the “Change Mode” button) as shown on the screen images below or can be selected via external control switches as optionally connected to the TSC 900 Programmable inputs. Refer to

Section 4 - Operating Instructions for further information.

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TSC 900 TRANSFER SWITCH CONTROLLER

3.4. AUTOMATIC SEQUENCE OF OPERATION

3.4.1. OPEN TRANSITION TRANSFER

Note: For specific device settings and ranges, refer to Section 6 - Factory Default

Programming. Under normal operating conditions, the transfer switch operates automatically during a failure and restoration of utility power and does not require operator intervention.

When utility supply voltage drops below a preset nominal value on any phase, an engine start delay circuit will be initiated. Following expiry of the engine start delay period an engine start signal (contact closure) will be given.

Once the engine starts, the transfer switch controller will monitor the generators voltage and frequency levels. Once the generator voltage and frequency rises above preset values, a warm up time delay will be initiated. Once the warm up timer expires, the transfer to utility supply signal will be removed (i.e. contact opening) and the transfer to generator supply signal (contact closure) will be given to the transfer switch mechanism. The load will then transfer from the utility supply (i.e. opening the utility power switching device) to the generator supply (closing the generator power switching device) to complete a break-before-make open transition transfer sequence.

transfer mechanism to pause in the “neutral position (i.e. with both transfer power

switching devices open) for the duration of the neutral delay timer setting, once the time delay expires, the re-transfer sequence will be completed.

An engine cooldown timer circuit will be initiated once the load has successfully retransferred back onto the utility supply. Following expiry of the cooldown delay period the engine start signal will be removed (remote start contact opened) to initiate stopping of the generator set.

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TSC 900 TRANSFER SWITCH CONTROLLER

3.4.2. CLOSED TRANSITION TRANSFER

For transfer switches equipped with the closed transition transfer option (i.e. ATS Model Code Digit #13 “Operation Type” 3 or 4), the TSC 900 is configured to provide additional logic for this application. When the TSC 900 controller receives an input signal for Closed Transition Transfer Mode, the TSC 900 is configured to operate as follows:

Under normal closed transition operating conditions, the transfer switch operates automatically during a failure and restoration of utility power and does not require operator intervention.

Once the engine starts, the transfer switch controller will monitor the generator voltage and frequency levels. When the generator voltage and frequency rises above preset values, a warm up time delay will be initiated. When the warm up timer expires the transfer to utility supply signal will be removed (logic contact(s) opening) and the transfer to generator supply signal (logic contact(s) closure) will be given to the transfer switch Power Switching Devices. The load will then transfer from the utility supply (i.e. opening the utility power switching device) to the generator supply (closing the generator power switching device) to complete a break-before-make open transition transfer sequence.

The generator will continue to supply the load until the utility supply has returned and the retransfer sequence is completed as follows: When the utility supply voltage is restored to above the preset values on all phases, a utility return delay circuit will be initiated. Following expiry of the utility return timer, the utility power-switching device will close when it is in synchronism with the generator supply. If the transfer switch is supplied with a Fast (Momentary) Closed Transition transfer control option, the generator power switching device will immediately trip within ~100 milliseconds after the utility power switching device closes to complete the “make-before-break” retransfer sequence. If the transfer switch is supplied with a “Soft-Load” Closed Transition transfer control option, the generator power switching device will remain closed for a longer time period to allow a soft-load power transfer sequence to be completed via external loading controller. The generator power switching device will then trip open to complete the “make-before-break” re-transfer sequence.

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An engine cooldown timer circuit will be initiated once the load has successfully retransferred back onto the utility supply. Following expiry of the cooldown delay period, the engine start signal will be removed (remote start contact opened) to initiate stopping of the generator set.

TSC 900 TRANSFER SWITCH CONTROLLER

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TSC 900 TRANSFER SWITCH CONTROLLER

3.4.3. AUTOMATIC LOAD SHED OPERATION

The TSC 900 can be configured for automatic load shedding operation by use of a programmable output contact. Under normal utility power conditions, the load shed

control is not activated. When an utility power failure occurs and the ATS transfer’s to

the generator supply, the load shed circuit is automatically initiated for a preprogrammed time delay setting. Once the Load shed initiate timer expires, the Load shed circuit is reset. Automatic Load shed can also be configured for automatic load shed based on generator under frequency and/or ATS load kW (over power) set points. Refer to Section 5.14 for programming instructions. The automatic sequence of operation is further described as per the following flow chart.

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TSC 900 TRANSFER SWITCH CONTROLLER

3.4.4. TEST MODE

3.4.4.1. ON LOAD TEST (OPEN TRANSITION TRANSFER)

When an operator selects an ON LOAD TEST mode, the ATS controller will initiate a simulated utility power failure condition. The transfer switch will operate as per a normal utility power fail condition with all normal time delays enabled. The neutral delay circuit logic will be active during transfer to and from the generator supply (i.e. when both sources of power are available). The transfer switch will remain on generator supply while in the Test mode. When the Test mode is manually canceled, the ATS will re-transfer back to the utility supply following the utility return delay, then the generator will cooldown before stopping.

3.4.4.2. ON LOAD TEST (CLOSED TRANSITION TRANSFER)

When a load test is initiated in the closed transition transfer mode, the generator will start and following its warm up delay, the generator will close its power-switching device when it is in synchronism with the utility supply. If the

transfer switch is supplied with a “Momentary” Closed Transition transfer control

option, the utility power switching device will immediately trip open within ~100 milliseconds after the generator power switching device closes to complete the

“make-before-break” transfer sequence. If the transfer switch is supplied with a “Soft-Load” Closed Transition transfer control option, the utility power switching

device will remain closed long enough to allow a soft-load power transfer sequence to be completed as controlled by an external device. The utility power switching device will then trip open to complete the “make-before-break” transfer sequence. The generator will continue to supply the load until the test mode has been removed and the re-transfer sequence is completed as follows: The utility power-switching device will close when it is in synchronism with the generator supply via external logic device. If the transfer switch is supplied with

a “Momentary” Closed Transition transfer control option, the generator power

switching device will immediately trip open within ~100 milliseconds after the

utility power switching device closes to complete the “make-before-break” retransfer sequence. If the transfer switch is supplied with a “Soft-Load” Closed

Transition transfer control option, the generator power switching device will remain closed long enough to allow a soft-load power transfer sequence to be completed as controlled by an external device. The generator power switching device will then trip open to complete the “make-before-break” re-transfer sequence.

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TSC 900 TRANSFER SWITCH CONTROLLER

3.4.5. ABNORMAL SEQUENCE OF OPERATION

3.4.5.1. GENERATOR FAILURE ON LOAD

Should the generator set fail while on load, the transfer switch will automatically re-transfer the load back to the utility supply if within nominal limits. The utility return timer will be bypassed in this condition.

NOTE:

This operating condition applies to a normal utility failure as well as any test condition.

3.4.5.2. TRANSFER SWITCH FAIL ALARM LOGIC

The TSC 900 controller contains logic to detect a transfer mechanism failure. Should a failure be detected, a forced transfer to the alternate supply will be initiated if the TSC 900 is programmed for force transfer. Refer to the programming Section 5 for further information in Force Transfer operation.

3.4.5.3. SERVICE ENTRANCE ATS

For Service Entrance Rated transfer switch applications, the transfer switch control logic will include signal the transfer switch mechanism to move to the

“Service Disconnected” position when Service Disconnect Operation is

required. In this mode the TSC 900’s transfer control outputs and Transfer Fail

feature is disabled. On return to normal operation, the Utility Power-Switching Device will be closed to the utility supply if available. Should the utility supply be out of limits the generator will be issued a start command and the load transfer to the generator supply once its warm-up time has expired. The ATS returns to Auto control and will return to the utility supply as previously describe for the appropriate ATS design type.

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3.5. GHC DISPLAY MAIN MENU PAGE DESCRIPTIONS

The GHC software provides the TSC 900 control and monitoring information which is visible on the GHC Display or remote PC. All screen page navigation is controlled by a touchscreen display using a “finger swipe” motion and/or button press actions. The GHC has preprogrammed display pages which are selected manually using the touchscreen display. The display pages are organized into the following main menu pages in software:

TSC 900 TRANSFER SWITCH CONTROLLER

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TSC 900 TRANSFER SWITCH CONTROLLER

LED

Label

Light Off

Light On

Light Flashing

Engine Start (RED)

Engine is not commanded to start/run

Engine is commanded to start/run

n/a

Exercise

(Yellow)

Exercise Schedule is not enabled or active

Exercise Schedule is enabled but not currently active

Exercise is currently active

Test

(Yellow)

Test is not active

Local Test is active (On Load or Off Load)

Remote Test is active

Load Shed (Yellow)

Load Shed is not active

Load Shed is activated

n/a

Alarm Icon –flashes when a new Alarm has been activated

Press to view active alarms

Security Icon - Settings Locked (Read only mode)

Press to access security login

Security Icon - Settings Un-Locked (Read/write mode)

Press to access security login

3.5.1. HOME PAGE

The Home Page is utilized as a summary control and monitoring screen for the ATS. This screen provides a mimic bus showing current ATS position, identifies which sources are energized, voltage levels and overall ATS operating mode. On three phase systems, all phase to phase voltages will be displayed for each source and load.

The mimic bus will automatically change color as follows:

 Utility –dark green = de-energized, light green = energized  Generator - dark green = de-energized, red = energized

Power Switching Device status is depicted as follows:

 Utility Closed: Generator Closed:

The following Status LEDs are shown on the Home page:

Test or Timed test modes can be activated from the Home page by press of the

“Change Mode” button which activates a pull down menu. Refer to OPERATING

INSTRUCTION section of this manual for operating procedures.

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+ 67 hidden pages

Marathon TSC 900 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual