Thomson TS 840 User Manual

TS 840

AUTOMATIC TRANSFER SWITCHES

INSTALLATION, OPERATING &

SERVICE MANUAL

PM057 Rev 8 10/01/25

9087A – 198th Street, Langley, BC Canada V1M 3B1 Ÿ Telephone [phone]

Telefax [phone] Ÿ E-Mail: [e-mail] Ÿ www.thomsontechnology.com

TS 840 TRANSFER SWITCH

TABLE OF CONTENTS

1. PRODUCT REVISION HISTORY 1

2. EQUIPMENT STORAGE 1

2.1. ENVIRONMENTAL CONDITIONS 1

3. NOTES TO INSTALLER 2

3.1. UPSTREAM CIRCUIT PROTECTIVE DEVICES/ELECTRICAL CONNECTIONS 2

3.2. TRANSFER SWITCHES WITH INTEGRAL OVER CURRENT PROTECTION 3

3.3. SYSTEM PHASING-HIGH LEG DELTA SYSTEMS 4

3.4. REMOTE START CONTACT FIELD WIRING 5

3.5. DIELECTRIC TESTING 5

3.6. INSTALLATION OF OPEN TYPE TRANSFER SWITCHES 5

3.7. MOUNTING OF ENCLOSED TRANSFER SWITCHES 5

4. GENERAL DESCRIPTION 8

4.1. PRODUCT MODEL CODE 10

4.2. TYPICAL COMMISSIONING PROCEDURES 11

5. GENERAL THEORY OF OPERATION 11

5.1. STANDARD AUTOMATIC TRANSFER SWITCH 11

5.2. SERVICE ENTRANCE AUTOMATIC TRANSFER SWITCH 12

5.3. TEST MODES 16

6. OVER CURRENT PROTECTION 16

6.1. STANDARD TS 840 AUTOMATIC TRANSFER SWITCH 16

6.2. OPTIONAL TS 840 AUTOMATIC TRANSFER SWITCH WITH INTEGRAL OVER
CURRENT PROTECTION 16

7. GENERAL NOTES ON SERVICING TRANSFER SWITCH MECHANISM 18

8. TRANSFER SWITCH MECHANISM OPERATION– 100A-800A, S STYLE 20

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8.1. MANUAL OPERATION 20

9. RECOMMENDED MAINTENANCE 22

10. FRONT VIEW (TYPICAL) 3 POLE 100A-250A S-STYLE TRANSFER MECHANISM23

11. FRONT VIEW (TYPICAL) 3 POLE 400A-800A S-STYLE TRANSFER MECHANISM
(MECHANISM FRONT COVER REMOVED) 24

12. FRONT VIEW (TYPICAL) 3 POLE 400A-800A S-STYLE TRANSFER MECHANISM25

13. CABLE TERMINAL INFORMATION 26

14. REQUIREMENTS FOR UPSTREAM CIRCUIT PROTECTIVE DEVICES 26

14.1. WITHSTAND CURRENT RATINGS (ALL MODELS WITHOUT INTEGRAL

OVERCURRENT PROTECTION OPTION) 26

14.2. INTERRUPTING CAPACITY CURRENT RATINGS (ALL MODELS WITH INTEGRAL

OVERCURRENT PROTECTION OPTION) 27

15. GROUND FAULT SITE TEST REQUIREMENTS 27

15.1. PERFORMANCE TEST 27

16. TROUBLESHOOTING 29

17. REPLACEMENT PARTS 31

18. PRODUCT RETURN POLICY 32

19. NOTES 33

20. PERFORMANCE TEST FORM 34

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1. PRODUCT REVISION HISTORY

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

Operating & Service Manual Version

Rev 0 02/06/17
Rev 1 04/11/19
Rev 2 05/03/ 08

Rev 3 05/05/17
Rev 4 06/05/08
Rev 5 07/07/31
Rev 6 08/01/07
Rev 7 08/03/05

Rev 8 10/01/25

Original release.
Change Controller From TSC 800 to TSC 80 Controller.
Changes to incorporate reversing style ATS Motor for 100-250A

transfer switches.
Revisions to Section 5 and Section 18.
Revisions to Section 15.
Changes to Incorporate new S Style 400A mechanism
Revisions to Appendix A
Changes to Incorporate new S Style mechanism (100A, 150A,

200A, 250A, 600A, 800A)
Changes to Incorporate Seismic Certification and Mounting

Requirements

Contact Thomson Technology, to obtain applicable instruction manuals or if in doubt about
any matter relating to installation, operation or maintenance. Soft copy of the most current
version is available at www.thomsontechnology.com.

NOTE: All information contained in this manual is for reference only and is subject

to change without notice.

2. EQUIPMENT STORAGE

The following procedures are required for correct storage of the transfer switch prior to installation.

2.1. ENVIRONMENTAL CONDITIONS

CAUTION!!!

Failure to store and operate equipment under the specified environmental conditions may
cause equipment damage and void warranty.

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TS 840 TRANSFER SWITCH

2.1.1. EQUIPMENT STORAGE

The transfer switch shall be stored in an environment with a temperature range not
exceeding -4° to +158° Fahrenheit (-20° to +70° Celsius) and a humidity range not
exceeding 5%-95% non-condensing. Before storing, unpack sufficiently to check for
concealed damage. If concealed damage is found, notify the ATS supplier and the
Carrier immediately. Repack with the original, or equivalent packing materials.
Protect from physical damage. Do not stack. Store indoors in a clean, dry, well
ventilated area free of corrosive agents including fumes, salt and concrete/cement
dust. Apply heat as necessary to prevent condensation.

2.1.2. EQUIPMENT OPERATING

The transfer switch shall be operated in an environment with a temperature range
not exceeding +5° to +122° Fahrenheit (-15° to +50° Celsius) and a humidity range
not exceeding 5%-95% non-condensing.

3. NOTES TO INSTALLER

Arc Flash and Shock Hazard. Will cause severe injury or death.

Do not open equipment until ALL power sources are disconnected

This equipment must be installed and serviced only by qualified electrical
personnel utilizing safe work practices and appropriate Personal Protective
Equipment (PPE). Failure to do so may cause personal injury or death

3.1. UPSTREAM CIRCUIT PROTECTIVE DEVICES/ELECTRICAL
CONNECTIONS

To ensure satisfactory installation of this equipment be sure to observe "Cable Terminal
Information” regarding power cable connection tightness and "Requirements for Upstream

DANGER!!!!

Circuit Protective Devices" located in this manual.

All mechanical and electrical connections must be checked for tightness prior to placing this
equipment in service to ensure proper operation and to validate applicable warranty
coverage.

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TS 840 TRANSFER SWITCH

3.2. TRANSFER SWITCHES WITH INTEGRAL OVER CURRENT PROTECTION

For models of transfer switch with integral over current protection, the over current
protection must be set prior to operation. The equipment will be shipped from the factory
with a long-time current setting of 100% (of the equipment rating) and maximum short­time/instantaneous current and time delay settings.

WARNING!

Do Not Energize this equipment until
device settings have been verified to
ensure proper system protection &
coordination. Failure to do so may
result in equipment failure.

Refer to Section 5.2.2 of this manual for additional information on operation of the Transfer
switch following an over current trip condition.

Refer to information supplied with the transfer switch documentation package for
adjustment procedures on the power switching units over current protection trip unit.
Contact the factory if any additional information is required.

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3.3. SYSTEM PHASING-HIGH LEG DELTA SYSTEMS

For systems using high leg delta 240V 3 phase 4 wire systems, connection of supply
conductors must have the correct phasing as shown below.

WARNING

Failure to match correct system
phasing will result in serious damage
to the TSC 80 controller.

Automatic Transfer

Switch (Utility Supply)

PH A

(UA)

PH B

(UB)

PH C

(UC)

Neural

(N)

B

(Orange)

(High Leg)

208V

C

(Yellow)

A

(Red)

240V 240V

120V 120V

N

(White)

Where transfer switches are supplied without power isolation transformers (PT1 &
PT2) for ATS control logic it is essential that the orientation of phase conductors of

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TS 840 TRANSFER SWITCH

the supply source be arranged such that the phase of highest potential with respect
to ground is not connected to the power supply inputs to the controller (A Phase for
both supplies). Failure to do so will result in equipment damage.
Per NEC Article 384-3 (f) “The B phase shall be that phase having the higher
voltage to ground on a 3-phase, 4-wire delta connected systems.”

3.4. REMOTE START CONTACT FIELD WIRING

As a minimum, the remote engine start control field wiring shall conform to the local
regulatory authority on electrical installations. 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.

3.5.1. Minimum #14 AWG (2.5mm2) wire size shall be used for distances up to

100ft (30m)1). For distances exceeding 100 ft. (30m) consult Thomson
Technology

3.5.2. Remote start contact wires should be run in a separate conduit.

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

3.5.4. An interposing relay may be required if field-wiring distance is excessively

long (i.e. greater than 100 feet (30m)) and/or if a remote contact has a
resistance of greater than 5.0 ohms.

3.5.5. The re mote start contact must be voltage free (i.e. dry contact). The use of a

“powered” contact will damage the transfer controller.

3.5. DIELECTRIC TESTING

Do not perform any high voltage dielectric testing on the transfer switch with the TSC
80 controller connected into the circuit as serious damage will occur to the controller.
All AC control fuses and control circuit isolation plugs connected to the TSC 80 must
be removed if high voltage dielectric testing is performed on the transfer switch.

3.6. INSTALLATION OF OPEN TYPE TRANSFER SWITCHES

Please refer to the factory for additional information.

3.7. MOUNTING OF ENCLOSED TRANSFER SWITCHES

Model TS840, TS870 and TS880 Automatic Transfer Switches and Automatic
Transfer and Bypass Isolation Switches in "standard" enclosures are seismic
certified under AC156 building code for non-structural components.

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"Standard" enclosures are all transfer switch enclosures Thomson Technology offers
in NEMA 1, NEMA 2, NEMA 3R and NEMA 4X for the above listed product. If a
customer requests a custom enclosure it would not be covered under the generic
certificate; if certification were a requirement Consult factory before ordering.
The Automatic Transfer Switches are qualified to the highest known level in North
America; based on site class D. Specifically this is a spectral acceleration of 342%.
The transfer switch must be installed per the anchoring details provided for seismic
qualification. The equipment can be mounted in alternate means and still qualify if a
qualified Civil Engineer designs the alternate method of anchoring.

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Anchoring Notes:

1. Anchoring must be designed according to IBC 2006 or latest version.

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2. The anchoring details shown are recommended according to the seismic
certification; design Engineer may use alternate anchors within the scope of IBC.

3. Wall anchors in concrete; use a typical concrete anchor as necessary.

4. Expansion anchors as shown to be installed according to manufacturer's
recommendation.

5. The 800-1200A NEMA 3R ATS enclosure may be floor/wall mounted or it may be
free standing (floor mounted only); If free standing it must be a minimum of 12"
(305mm) away from pipes, conduits or other obstructions to allow for sway during a
seismic event.

4. GENERAL DESCRIPTION

Thomson Technology TS 840 series of Automatic Transfer Switches employ two mechanically
interlocked enclosed contact power switching units and a microprocessor based controller to
automatically transfer system load to a generator supply in the event of a utility supply failure.
System load is then automatically re-transferred back to the utility supply following restoration of
the utility power source to within normal operating limits.

The standard TS 840 series Automatic Transfer Switch is rated for 100% system load and requires
upstream over current protection. The TS 840 Automatic Transfer Switch may be supplied with
optional integral over current protection within the enclosed contact power switching units for
applications such as Service Entrance Rated equipment. Refer to Section 6 of this manual for
detailed information on over current protection.

The TS 840 series transfer switches use a type TSC 80 microprocessor based controller which
provides all necessary control functions for fully automatic operation. The TSC 80 controller is
mounted on the door of the transfer switch enclosure and operating status is shown via LED lights.
For further information on the TSC 80 Transfer Controller, refer to separate instruction manual
PM063.

The power switching devices used for the Utility and Generator sources are operated by an
electrically driven motor mechanism in the transfer switch. The transfer switch motor utilizes the
power from the source to which the electrical load is being transferred. The mechanism provides a
positive mechanical interlock to prevent both power switching units from being closed at the same
time, which allows an open transition, “break-before-make” transfer sequence. The TSC 80

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transfer controller provides a standard neutral position delay timer to allow adequate voltage decay
during transfer operation to prevent out of phase transfers.
Note: For the purpose of this manual, the following standard nomenclature is utilized:

• Utility: to indicate the source of primary power

• Generator: to indicate the source of standby power

• Power switching device: to indicate the transfer switch power switching device

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