Thomson TSC 80E V2.1 User Manual

TSC 80e

TRANSFER SWITCH CONTROLLER

INSTALLATION, OPERATING &

SERVICE MANUAL

Software Version 2.2

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

Telefax (604) 888-3381  E-Mail: info@thomsontechnology.com  www.thomsontechnology.com

PM091 Rev 1 09/02/27

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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TSC 80e TRANSFER SWITCH CONTROLLER

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

TSC 80e TRANSFER SWITCH CONTROLLER

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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TSC 80e TRANSFER SWITCH CONTROLLER

1.2. GENERAL INFORMATION

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.

NOTE:

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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TSC 80e TRANSFER SWITCH CONTROLLER

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.

Auto m atic Transfer

Switch (U tility Supply)

PH A

(U A)

240V 240V

PH B

(U B)

(Or ange )

(Hi gh L eg )

20 8V

PH C

(U C )

Ne u ra l

(N )

(R ed)

12 0V 120V

(Ye llow)

(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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TSC 80e TRANSFER SWITCH CONTROLLER

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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TSC 80e TRANSFER SWITCH CONTROLLER

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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TSC 80e TRANSFER SWITCH CONTROLLER

• 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

TB7

BT1

REAL TIME CLOCK BATTERY

SYS OK

PROG 2

PROG 3

PROG 1

ENG STOP

TRANSFORMER

XFER UTIL

XFER GEN

LD ON GEN

(PROG 4)

LD ON UTIL

(PROG 5)

TB6

TB2-5

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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TSC 80e TRANSFER SWITCH CONTROLLER

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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TSC 80e TRANSFER SWITCH CONTROLLER

• 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 de-

energized

• 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 & daylight-

savings 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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TSC 80e TRANSFER SWITCH CONTROLLER

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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TSC 80e TRANSFER SWITCH CONTROLLER

3Ø, 4W 208/380/480/600VAC DIRECT SENSING

TSC 80e

VOLTAGE INPUTS

600VAC L-L, 347VAC L-N 480VAC L-L, 277VAC L-N 380VAC L-L, 220VAC L-N 208VAC L-L, 120VAC L-N

PT REQUIRED FOR TRANSFER SWITCH MECHANISM POWER

(MUST BE SIZED TO SUIT POWER REQUIREMENTS).

NOTE: UTILITY VOLTAGE SENSING AND

CONTROL POWER SHOWN ONLY.

120

GRD

BA C N

GRD

SINGLE PHASE, 3W 120/240VAC DIRECT SENSING

TSC 80e

NO CONNECTION

GRD

VOLTAGE INPUTS

240VAC L-L, 120VAC L-N

NOTE: UTILITY VOLTAGE SENSING SHOWN ONLY.

L2L1 N

GRD

3Ø, 4W 120/240V HIGH LEG DELTA DIRECT CONNECTION

TSC 80e

120V

GRD

BA C N

GRD

B C

NOTE: FOR HIGH LEG DELTA SYSTEMS PHASING OF CUSTOMER SUPPLY MUST BE CONNECTED AS SHOWN ABOVE. FAILURE TO COMPLY WILL RESULT IN DAMAGE TO CONTROLLER.

NOTE: UTILITY VOLTAGE SENSING AND CONTROL POWER SHOW N ONLY.

3Ø, 3W DELTA PT's

TSC 80e

120

GRD

120

PT REQUIRED FOR TRANSFER SWITCH MECHANISM POWER

(MUST BE SIZED TO SUIT POWER REQUIREMENTS).

TSC80e CONTROLLER MUST BE PROGRAMMED FOR CORRECT

PT RATIO AND SECONDARY PT VOLTAGE IN SOFTWARE

NOTE: UTILITY VOLTAGE SENSING SHOWN ONLY.

120

GRD

SECONDARY PT VOLTAGE

120VAC L-L [NO NEUTRAL]

NOTE: ØB IS GROUNDED

BA C

FIGURE 3

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TSC 80e TRANSFER SWITCH CONTROLLER

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 Contact #1

Programmable Output Contact #2

Programmable Output Contact #3

Programmable Output Contact #4

Programmable Output Contact #5

Isolated Form C contact (10A, 120VAC/250VAC 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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TSC 80e TRANSFER SWITCH CONTROLLER

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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TSC 80e TRANSFER SWITCH CONTROLLER

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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