Thomson TSC 80E V2.1 Manual

TSC 80e

TRANSFER SWITCH CONTROLLER

INSTALLATION, OPERATING &

SERVICE MANUAL

Software Version 2.2

PM091 Rev 1 09/02/27

9087A – 198th Street, Langley, BC Canada V1M 3B1 Telephone [phone] Telefax [phone] E-Mail: [e-mail] www.thomsontechnology.com

TSC 80e TRANSFER SWITCH CONTROLLER

	TABLE OF CONTENTS
1.	INTRODUCTION	1
	1.1. PRODUCT REVISION HISTORY	1
	1.2. GENERAL INFORMATION	2
	1.3. NOTES TO TRANSFER SWITCH INSTALLER	2
	1.3.1. SYSTEM VOLTAGE	2
	1.3.2. SYSTEM PHASING - HIGH LEG DELTA SYSTEMS	3
	1.3.3. REMOTE START CONTACT FIELD WIRING	4
	1.3.4. DIELECTRIC TESTING	4
2.	DESCRIPTION	5
	2.1. LEXAN FACEPLATE	5
	2.2. PRINTED CIRCUIT BOARD	7
	2.2.1. TERMINAL BLOCKS	8
	2.2.2. DIAGNOSTIC LED’S	8
	2.3. TSC 80e CONTROLLER FEATURES	9
	2.4. APPLICATION INFORMATION	11
	2.4.1. AC VOLTAGE SENSING INPUT	11
	2.4.2. AC CONTROL POWER INPUT	13
	2.4.3. OUTPUTS	13
3.	OPERATING INSTRUCTIONS	14
	3.1. AUTOMATIC SEQUENCE OF OPERATION	14
	3.1.1. NORMAL OPERATION	14
	3.1.2. ABNORMAL OPERATION	15
	3.2. TEST MODES	17
	3.2.1. UTILITY POWER FAIL SIMULATION (LOAD TEST)	17
	3.2.2. AUTOMATIC PLANT EXERCISE TEST	18
	3.2.3. FOUR FUNCTION REMOTE TEST (FTS4 OPTION)	19
	3.2.4. REMOTE TEST	20
	3.3. TRANSFER FAIL FAULT RESET	20
	3.4. LAMP TEST	21
	3.5. TIMER BYPASS	21
	3.6. TSC 80e LCD DISPLAY OPERATION	22
	3.6.1. LCD DISPLAY SCREENS	22
	3.6.2. LCD DISPLAY MODE OPERATION	25
	3.6.3. SYSTEM STATISTICS	25

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	3.6.4. DATALOG MENU	26
4.	TSC 80E SOFTWARE PROGRAMMING INSTRUCTIONS	27
4.1. PASSWORDS		27
	4.1.1. USER READ (VIEW ONLY MODE)	27
	4.1.2. USER READ / WRITE MODE	27
	4.1.3. MASTER READ / WRITE MODE	27
	4.1.4. PASSWORD ENTRY PROCEDURE	28
4.2. SOFTWARE PROGRAMMING PROCEDURE		28
4.3. PROGRAMMING DISPLAY MAIN MENU SCREENS		30
4.4. QUICK GUIDE VOLTAGE CHANGE PROGRAMMING PROCEDURE		31
4.5. QUICK GUIDE PROGRAMMABLE OUTPUTS PROGRAMMING PROCEDURE		32
4.6. PROGRAMMING DISPLAY SUB-MENU DESCRIPTIONS		33
	4.6.1. PASSWORD ENTRY & RESET	33
	4.6.2. SYSTEM DATE & TIME	34
	4.6.3. AUTO EXERCISE TIMER	34
	4.6.4. SYSTEM OPTIONS	36
	4.6.5. SYSTEM CONFIG	36
	4.6.6. VOLTAGE CALIBRATION	41
	4.6.7. UTILITY VOLTAGE SETPOINTS	44
	4.6.8. GENERATOR VOLTAGE & FREQUENCY SETPOINTS	45
	4.6.9. SYSTEM TIMING DELAYS	45
	4.6.10. PROGRAMMABLE OUTPUTS	47
	4.6.11. SYSTEM STATISTICS	50
	4.6.12. DATALOGS	51
4.7. TSC 80e FACTORY DEFAULT PROGRAMMING SETTINGS		52
5.	TSC 80E TYPICAL CONNECTION DIAGRAM	53
6.	TSC 80E SPECIFICATIONS	54
7.	TROUBLESHOOTING	55
8.	TSC 80E REPLACEMENT PARTS	56
9.	PRODUCT RETURN POLICY	57
10.	NOTES	58

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1.INTRODUCTION

1.1.PRODUCT REVISION HISTORY

The following information provides an historical summary of changes made to this product

since the original release.

Software Version

2.2 09/02/27	Software revised for TSC 80 Controllers. No changes to TSC 80e
	Controller features or operation.
2.1 09/01/21	Software updated to incorporate Configurable PT Ratio for 3 phase,
	3 wire applications
2.0 08/08/14	Original software release for TSC 80e

Operating & Service Manual Version

Rev 0 09/01/19 Original release of dedicated Manual for TSC 80e

Contact Thomson Technology, to obtain applicable instruction manuals. Soft copy of most current version is available at www.thomsontechnology.com.

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1.2.GENERAL INFORMATION

NOTE:

Installations should be done in accordance with all applicable electrical regulation codes as required.

The following information is provided for general information only pertaining to TSC 80e Transfer Switch Controllers installed in a Thomson Technology Automatic Transfer Switch as applied in a typical site installation. For specific site installation information, consult Thomson Technology as required.

CAUTION

contents subject to damage by

STATIC ELECTRICITY

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.

•Discharge body static charge before handling the equipment (contact a grounded surface and maintain contact while handling the equipment, a grounded 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 grounded surfaces and only use an anti-static bag for transporting the equipment.

1.3.NOTES TO TRANSFER SWITCH INSTALLER

1.3.1. SYSTEM VOLTAGE

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

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system voltage. If the transfer switch requires reconfiguring, the TSC80e controller will require re-programming as well.

WARNING

Failure to confirm and match transfer switch voltage with the system voltage could cause serious equipment damage.

1.3.2. SYSTEM PHASING - HIGH LEG DELTA SYSTEMS

When the transfer switch is connected to a 3-phase 4-wire delta systems, the “High” leg (Phase B, colored Orange), must be connected to Phase B of the Utility and/or Generator supply. This will ensure the ATS control power, which is internally connected between Phase A and Neutral is maintained at 120VAC. Refer to figure below for further details.

WARNING

Failure to match correct system phasing

will result in serious damage to the

TSC 80e controller.

Automatic Transfer

Switch (Utility Supply)

PH A	PH B	PH C	Neural
(UA)	(UB)	(UC)	(N)

B

(Orange)

(High Leg)

240V

208V

240V

A

120V

120V

C

(R ed)

(Yellow)

N

(W hite)

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CAUTION!!!

All installation and/or service work performed must be done by qualified personnel only. Failure to do so may cause personal injury or death.

1.3.3. 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.

1.3.3.1.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.

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

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

1.3.3.4.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.

1.3.3.5.The remote start contact provided is voltage free (i.e. dry contact). Refer to the “TSC 80e Typical Connection Diagram” on page 52 for terminal interface and contact voltage/current ratings or page 13 for specifications on output contact ratings. Applying voltage or current in excess of the ratings will damage the controller and is not cover by Thomson Technology’s limited warranty.

1.3.4. DIELECTRIC TESTING

Do not perform any high voltage dielectric testing on the transfer switch with the

TSC80e 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

TSC80e must be removed if high voltage dielectric testing is performed on the transfer

switch.

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2.DESCRIPTION

The TSC 80e controller utilizes microprocessor-based design technology, which provides high accuracy for all voltage sensing and timing functions. The TSC 80e is factory configured to control all the operational functions and display features of the automatic transfer switch.

The TSC 80e controller consists of two parts; a Lexan faceplate, which is mounted externally on the transfer switch door, and a printed circuit board (PCB), which is mounted inside the transfer switch on the enclosure door. The TSC 80e PCB contains a built-in LCD display that is visible from the front panel faceplate. The Lexan faceplate contains operation/data-acquisition/programming pushbuttons and indication LEDs.

2.1.LEXAN FACEPLATE

The TSC 80e Controller Lexan faceplate is shown as in FIGURE 1. The Lexan pushbuttons and LED lights are connected to the main PCB via plug-in ribbon cable. The main features of the Lexan faceplate are described as follows with reference to FIGURE 1.

Utility Supply Available LED light

Load on Utility supply LED light

Load on Generator supply LED light

Generator Supply Available LED light

ATS Load Bus Energized LED light

Utility Power Fail Test Mode Pushbutton (Program value DECREMENT/DOWN Pushbutton) & LED light

Auto Generator Exercise Mode Pushbutton (Program value INCREMENT/UP Pushbutton) & LED light

LCD Display Screen Viewing Window

Programming Escape/Data Log review Pushbutton

Programming Enter Pushbutton

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FIGURE 1 - TSC 80e Controller Lexan Faceplate

•ESC pushbutton. The ESC function is used to “ESCAPE” or exit the last field or programming menu. The program menu is a drill down format; by pressing the ESC button the program steps back one layer at a time until it escapes/exits the program menu. The ESC function can also be used to view the controllers Data Logs that are stored.

•DOWN pushbutton. The DOWN function is used to change or decrement values while in the programming mode and is used to scroll down through the status menus or programming sub menus to the next item.

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•UP pushbutton. The UP function is used to change or increment a programming value while in the programming mode and is used to scroll up through the status menus or programming sub menus to the previous item.

•ENTER pushbutton. The ENTER function is used to access the Program menus and “enters” and accept new programming or operating mode changes after a new value has been selected.

2.2.PRINTED CIRCUIT BOARD

38											37
								PROG 2
								PROG 3
								PROG 1
44	TB7									TB6	29
								ENG STOP			28
											1
								TRANSFORMER
BT1								TRANSFORMER
	REAL TIME							XFER UTIL
						SYS OK
	CLOCK
	BATTERY							XFER GEN
								LD ON GEN
								(PROG 4)
								LD ON UTIL
								(PROG 5)
											11
											TB2-5
	1	2	3	4	5	6	7	8	9	10
TB1

FIGURE 2

The printed circuit board (PCB) is shown in FIGURE 2. The PCB contains the following user

interface items:

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2.2.1. TERMINAL BLOCKS

Terminal blocks are located on the PCB as follows:

TB1 High voltage sensing terminal block (120-600VAC).

WARNING

Voltage sensing circuits are capable of lethal voltages while energized. Standard safety procedures should be followed and be performed by qualified personnel only. Failure to do so may cause personnel injury and/or death.

TB2-TB6 Transfer control terminal block for 120VAC control power and input/output circuits.

TB7 Low voltage control inputs (5VDC internally powered, switched to terminal 38).

2.2.2. DIAGNOSTIC LED’S

The TSC 80e controller provides diagnostic LED lights, which are mounted on the printed circuit board as per FIGURE 2. Their functions are described as follows:

SYS OK	LED flashes on and off at irregular intervals, which indicates
	the microprocessor is functioning normally.
XFER TO UTILITY	LED illuminates whenever the TSC 80e is initiating a signal
	to transfer to the Utility supply. (UP transfer contact as noted
	on the electrical schematic is closed)
XFER TO GEN	LED illuminates whenever the TSC 80e is initiating a signal
	to transfer to the Generator supply. (GP transfer contact as
	noted on the electrical schematic is closed)
ENG STOP	LED illuminates whenever the TSC 80e is initiating an
	ENGINE STOP (remote start contact is open).
PROG 1	LED illuminates whenever the Programmable output Relay
	#1 is turned on (relay on the circuit board is energized).
PROG 2	LED illuminates whenever the Programmable output Relay
	#2 is turned on (relay on the circuit board is energized).
PROG 3	LED illuminates whenever the Programmable output Relay
	#3 is turned on (relay on the circuit board is energized).

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LD ON GEN (PROG 4) LED illuminates whenever the Programmable output Relay #4 is turned on (relay on the circuit board is energized). Factory default function is “Load on Gen”.

LD ON UTIL (PROG 5) LED illuminates whenever the Programmable output Relay #5 is turned on (relay on the circuit board is energized). Factory default function is “Load on Utility”.

2.3.TSC 80e CONTROLLER FEATURES

The Thomson Technology TSC 80e Transfer Switch Controller utilizes the latest advancements in microprocessor technology, printed circuit board assembly and software for control of automatic transfer switches. The TSC 80e is the second generation of microprocessor-based transfer switch controllers from Thomson Technology, and reflects over 30 years of transfer switch control experience. The TSC 80e is factory configured to monitor, display and control all operational functions of the automatic transfer switch. All voltage sensors and timers are fully user adjustable utilizing software configuration. The microprocessor design provides high accuracy for all voltage sensing and timing functions as well as providing many standard features.

•Utility AC voltage sensing (true RMS) – 120-600V single phase or 3 phase

•Generator AC voltage sensing (true RMS) – 120-600V single phase or 3 phase

•Generator AC frequency sensing

•Utility under voltage control setpoint 70 - 95% (adjustable)

•Generator under voltage control setpoint 70 - 95% (adjustable)

•Generator under frequency control setpoint 70 - 90% (adjustable)

•Engine warm-up timer 0-60 sec. (adjustable)

•Utility return timer 0-30 min. (adjustable)

•Engine start timer 0-60 sec. (adjustable)

•Engine cooldown timer 0-30 min. (adjustable)

•Neutral position delay timer 0-60 sec. (adjustable)

•Local utility power fail simulation test pushbutton & LED, door mounted

•Remote utility power fail simulation test pushbutton input (via terminal block)

•Load on utility supply & load on generator supply LED’s, door mounted

•Utility and generator source available LED’s, door mounted

•Weekly plant exercise timer (30 min. on load) manually initiated

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•Local plant exercise initiate pushbutton & LED, door mounted

•Engine start contact (10A, 120/240VAC resistive max.)

•Transfer fail/forced transfer logic

•Automatic force transfer to alternate supply should load voltage become deenergized

•50 or 60Hz capable (120V control power)

•Remote Load Test/Peak Shave Input

•LCD Display: Built-in, front faceplate mounted LCD Display for monitoring 3 phase Utility/Generator voltage, system frequency and timer countdown operation

•Front Panel Programming: All controller set points can be programmed using built-in faceplate mounted pushbuttons & LCD display with password security

•Load Disconnect Contact (LDC): Integrated Load Disconnect Contact (LDC) feature provides pre/post transfer control to signal external building systems such as elevators during transfer operations

•Generator Exercise Timer (EXT): Integrated Generator Exercise Timer (EXT) with easy to use 4 event, 7-14-21-28 Day, On-load or Off-load Programmability

•Real-time Clock: On Board Real-time clock c/w battery back-up & daylightsavings programming functionality

•Event Data Logging: Data logging of key events including total transfers to generator, total utility power failures, load on utility hours, load on generator hours and utility or generator voltage/ frequency data at time of fault

•5 Programmable Output Contacts: Additional Programmable Output Contact rated 10A, 120/240V resistive, Form C with the following available functions: Fail to Transfer, Load on Utility, Load on Gen, Utility Power Available (UPA), Generator Power Available (GPA), ATS Not in Auto, ATS in Auto, Transfer to Gen, Transfer to utility, Switch failure, and limit switch failure.

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2.4.APPLICATION INFORMATION

2.4.1. AC VOLTAGE SENSING INPUT

The TSC 80e can accept direct AC voltage sensing inputs on the generator and utility supplies from 120-600VAC (nominal). Note: Direct input voltage sensing can only be used when the system utilizes a 3 phase, 4 wire distribution system which has the neutral conductor solidly grounded. For 3 phase, 3 wire systems (i.e. no neutral) or high voltage systems, potential transformers must be used. Refer to FIGURE 3 for voltage sensing connections.

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3Ø, 4W 208/380/480/600VAC DIRECT SENSING							SINGLE PHASE, 3W 120/240VAC DIRECT SENSING
TSC 80e			A	B	C	N	TSC 80e	L1 L2	N
						GRD			GRD
1							1
2							2
3							3
							NO CONNECTION
25		1					10
26	120						25
24	GRD						26
	GRD						24
							GRD
VOLTAGE INPUTS
600VAC L-L, 347VAC L-N
480VAC L-L, 277VAC L-N
380VAC L-L, 220VAC L-N							VOLTAGE INPUTS
208VAC L-L, 120VAC L-N							240VAC L-L, 120VAC L-N

	1	PT REQUIRED FOR TRANSFER SWITCH MECHANISM POWER	NOTE: UTILITY VOLTAGE SENSING SHOWN ONLY.
		(MUST BE SIZED TO SUIT POWER REQUIREMENTS).
		NOTE: UTILITY VOLTAGE SENSING AND
		CONTROL POWER SHOWN ONLY.
	3Ø, 4W 120/240V HIGH LEG DELTA DIRECT CONNECTION		3Ø, 3W DELTA PT's

TSC 80e

A

B

C

N

TSC 80e

A

B

C

GRD

1

1

2

2

120

3

3

120

GRD

25

2

25

1

26

120V

26

120

24

24

GRD

GRD

GRD

A

N

SECONDARY PT VOLTAGE

120VAC L-L [NO NEUTRAL]

NOTE: ØB IS GROUNDED

B

C

1

PT REQUIRED FOR TRANSFER SWITCH MECHANISM POWER

(MUST BE SIZED TO SUIT POWER REQUIREMENTS).

NOTE:

FOR HIGH LEG DELTA SYSTEMS PHASING OF CUSTOMER SUPPLY MUST

TSC80e CONTROLLER MUST BE PROGRAMMED FOR CORRECT

BE CONNECTED AS SHOWN ABOVE. FAILURE TO COMPLY WILL RESULT IN DAMAGE

2

PT RATIO AND SECONDARY PT VOLTAGE IN SOFTWARE

TO CONTROLLER.

NOTE: UTILITY VOLTAGE SENSING AND CONTROL POWER SHOWN ONLY.	NOTE: UTILITY VOLTAGE SENSING SHOWN ONLY.

FIGURE 3

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2.4.2. AC CONTROL POWER INPUT

The TSC 80e is factory supplied for 120VAC (nominal) control power input voltage. Independent AC control power is required from both utility and generator supplies. AC control power is utilized for internal TSC 80e control circuits and external control device loads. The TSC 80e requires approximately 6 VA power for internal control circuits. The maximum external load is limited by output contact ratings (i.e. 10A resistive, 120VAC). Total AC control power requirements for each supply must be determined by adding both internal and external load requirements.

2.4.3. OUTPUTS

The TSC 80e provides the following types of output circuits:

Engine Start Contact	Isolated Form B contact (10A, 120VAC Resistive)
Transfer to Utility Output	120VAC, 10A (Resistive) powered output contact
Transfer to Generator Output	120VAC, 10A (Resistive) powered output contact
The TSC 80e provides the following additional output circuits:
Programmable Output	Isolated Form C contact (10A, 120VAC/250VAC
Contact #1	Resistive)
Programmable Output	Isolated Form C contact (10A, 120VAC/250VAC
Contact #2	Resistive)
Programmable Output	Isolated Form C contact (10A, 120VAC/250VAC
Contact #3	Resistive)
Programmable Output	Isolated Form C contact (10A, 120VAC/250VAC
Contact #4	Resistive)
Programmable Output	Isolated Form C contact (10A, 120VAC/250VAC
Contact #5	Resistive)

Interposing relays are required between the TSC 80e outputs and the end device if loads exceed the output current rating.

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3.OPERATING INSTRUCTIONS

To operate the TSC 80e controller and associated transfer switch using the front faceplate pushbuttons, refer to the following detailed operating instruction sub-section descriptions.

3.1.AUTOMATIC SEQUENCE OF OPERATION

3.1.1. NORMAL OPERATION

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 (70 - 95% of rated adjustable) on any one phase, an engine start delay will be initiated and the transfer to utility supply signal will be removed (i.e. contact opening). Following expiry of the engine start delay period (0 - 60 sec. adjustable) an engine start signal will be given (contact closure, relay drops out to initiate start sequence).

Once the engine starts, the transfer switch controller will monitor the generators voltage and frequency levels. When the generator voltage and frequency rises above preset values (70 - 95% nominal adjustable) the Engine Warm-up timer will be initiated. After the Engine Warm-up timer expires (0-60 sec. Adjustable), 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 to the generator supply via motor driven mechanism (Neutral Delay is bypassed on utility failure detection).

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 present values (70 - 95% of rated adjustable) on all phases, a transfer return delay circuit will be initiated. Following expiry of the utility transfer return timer (0 - 30 min. adjustable), the transfer to generator supply signal will be removed (contact opening), then the transfer to utility supply signal (contact closure) will be given to the transfer switch mechanism. The load will then be transferred from the generator supply back to the utility supply. During the utility re-transfer sequence a neutral positioning delay circuit will cause the 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 (0-30 seconds adjustable) setting. Once the neutral delay expires, the re-transfer sequence will be completed.

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An engine cooldown timer circuit will be initiated once the load is transferred from the generator supply. Following expiry of the cooldown delay period (0 - 30 min. adjustable) the engine start signal will be removed (contact opening) to initiate stopping of the generator set.

3.1.2.ABNORMAL OPERATION

3.1.2.1.TEST CONDITION

A test pushbutton on the transfer switch shall signal a simulated utility power fail signal to the transfer switch controller. The transfer switch shall operate as per a normal utility power fail condition. 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 shall remain on generator supply until the test mode is terminated. It will then retransfer back to the utility supply following expiry of the transfer return timer and then continue to operate the generator set for its cooldown period then stop.

3.1.2.2.GENERATOR FAILURE ON LOAD

Should the generator set fail while on load, the transfer switch shall retransfer the load back to the utility supply if within nominal limits. The utility return and neutral delay timers will be bypassed in this condition.

NOTE

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

3.1.2.3.TRANSFER SWITCH FAIL ALARM LOGIC

The TSC 80e controller contains logic to detect a transfer mechanism failure. Should a failure be detected, a forced transfer to the alternate supply will be initiated. Detailed logic operation is as follows:

NOTE

Disabling of the “TRANSFER SWITCH FAIL” feature is possible by selecting the “Disconnected” position on “Service Entrance

Models” or by a closure between terminals 38 & 42 on the TSC 80e. In these situations the TSC 80e controller will not verify that the transfer mechanism has operated correctly to provide power to the load bus.

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