Thomson TSC 80 V2.1 User Manual

TSC 80

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

PM063 Rev 7 09/02/27

TSC 80 TRANSFER SWITCH CONTROLLER

TABLE OF CONTENTS

1. INTRODUCTION 1

1.1. PRODUCT REVISION HISTORY 1

1.2. GENERAL INFORMATION 2

1.3. SERVICE DISPLAY MODULE (SDM) 3

1.4. NOTES TO TRANSFER SWITCH INSTALLER 3

1.4.1. SYSTEM VOLTAGE 3

1.4.2. SYSTEM PHASING-HIGH LEG DELTA SYSTEMS 3

1.4.3. REMOTE START CONTACT FIELD WIRING 4

1.4.4. DIELECTRIC TESTING 5

2. DESCRIPTION 6

2.1. LEXAN FACEPLATES 6

2.2. PRINTED CIRCUIT BOARD 8

2.2.1. TERMINAL BLOCKS 8

2.2.2. DIAGNOSTIC LED’S 9

2.2.3. ADJUSTMENT POTENTIOMETERS 10

2.2.4. CONFIGURATION JUMPERS 10

2.3. TSC 80 CONTROLLER FEATURES 10

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 20

3.5. TIMER BYPASS 21

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TSC 80 TRANSFER SWITCH CONTROLLER

4. TSC 80 CONFIGURATION INSTRUCTIONS 22

4.1. CONFIGURATION JUMPERS 22

4.1.1. SYSTEM VOLTAGE 22

4.1.2. SYSTEM FREQUENCY 25

4.1.3. SYSTEM PHASES 25

4.1.4. GEN EXERCISE LOAD TEST MODE (NO XFER) 26

4.1.5. SECURE 26

4.2. TSC 80 ADJUSTMENT POTENTIOMETERS 27

4.2.1. UTILITY UNDER VOLTAGE SETPOINT 28

4.2.2. GENERATOR UNDERVOLTAGE SETPOINT 29

4.2.3. GENERATOR UNDER FREQUENCY SETPOINT 29

4.2.4. ENGINE START DELAY 30

4.2.5. ENGINE WARMUP DELAY 31

4.2.6. ENGINE COOLDOWN DELAY 31

4.2.7. UTILITY RETURN DELAY 31

4.2.8. NEUTRAL DELAY 31

5. TSC 80 TYPICAL CONNECTION DIAGRAM 32

6. TSC 80 SPECIFICATIONS 33

7. TROUBLESHOOTING 34

8. TSC 80 REPLACEMENT PARTS 36

9. PRODUCT RETURN POLICY 36

10. NOTES 37

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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 80 TRANSFER SWITCH CONTROLLER

1.0 04/11/19

1.1 05/05/10

Original version

Software updated to incorporate the following:

 Revise potentiometer control directions to match revised

printed circuit board silkscreen text.

 Change operation associated to “secure” configuration

jumper. Enable remote load test to be activated if secure jumper is ON.

1.2 05/10/31

1.3 05/11/05

2.0 08/08/14

2.1 09/01/01

Beta Test Software-Not released for production

Software updated to change some internal default timer settings

Software updated to incorporate TSC 80e Option

Software updated to incorporate Configurable PT Ratio for TSC 80e Option

2.2 09/02/27

Software revised to correct 7-Day Genset Exercise Operation in TSC 80 Controllers utilizing version 2.0 and 2.1software.

Operating & Service Manual Version

Rev 0 04/11/19

Rev 1 05/05/10

Rev 2 05/12/15

Rev 3 08/08/01

Rev 4 08/08/18

Rev 5 09/01/01

Thomson Technology, to obtain applicable instruction manuals. Soft copy of most current

Original release

The following changes have been incorporated:

 Add changes for revised TSC 80 Software version 1.1.

 Add new Environmental Section

 Miscellaneous changes

Add changes for revised TSC 80 Software version 1.3.

Add changes for TC80e Option

Revised Default Settings for TSC 80E

Manual changed to dedicated TSC 80 manual (removed TSC 80E references)

version is available at www.thomsontechnology.com.

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TSC 80 TRANSFER SWITCH CONTROLLER

1.2. GENERAL INFORMATION

The following information is provided for general information only pertaining to TSC 80

transfer switch controllers. For information on the TSC 80e controller refer to product manual

PM091.

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 80

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.

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TSC 80 TRANSFER SWITCH CONTROLLER

1.3. SERVICE DISPLAY MODULE (SDM)

An optional hand held, plug-in Service Display Module (SDM) is available for the TSC 80

Transfer Controller. The SDM module provides an LCD screen to display additional detailed

information on the operation and settings of the TSC 80 controller for simplified

servicing/trouble shooting procedures. For detailed information, refer to the separate SDM

module instruction manual (PM065).

1.4. NOTES TO TRANSFER SWITCH INSTALLER

1.4.1. 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

system voltage. If the transfer switch requires reconfiguring, the TSC 80 controller will

require reconfiguration as well.

WARNING

Failure to confirm and match transfer

switch voltage with the system voltage

could cause serious equipment damage.

1.4.2. SYSTEM PHASING-HIGH LEG DELTA SYSTEMS

When the transfer switch is connected to 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 80 controller.

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TSC 80 TRANSFER SWITCH CONTROLLER

Auto matic T ransfer

Switch (Utility Supply)

PH A

(U A )

PH B

(U B )

PH C

(U C )

Neu ral

(N )

(O ra ng e)

(High Le g)

208V

(Ye llow )

(R ed )

240V 240V

120V 120V

(W hite )

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.

1.4.3. 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.

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TSC 80 TRANSFER SWITCH CONTROLLER

1.4.3.1.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.

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

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

1.4.3.4.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.

1.4.3.5.The remote start contact must be voltage free (i.e. dry contact). The use of a “powered” contact will damage the transfer controller.

1.4.4. DIELECTRIC TESTING

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

80controller 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.

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TSC 80 TRANSFER SWITCH CONTROLLER

2. DESCRIPTION

The TSC 80 controller utilizes microprocessor-based design technology, which provides high

accuracy for all voltage sensing and timing functions. The TSC 80 is factory configured to control all

the operational functions and display features of the automatic transfer switch.

The TSC 80 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.

2.1. LEXAN FACEPLATES

The TSC 80 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 & LED light

 Auto Generator Exercise Mode Pushbutton & LED light

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TSC 80 TRANSFER SWITCH CONTROLLER

FIGURE 1- TSC 80 Controller Lexan Faceplate

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TSC 80 TRANSFER SWITCH CONTROLLER

2.2. PRINTED CIRCUIT BOARD

JP5

600V 480V 380V 240V

50HZ 1 Phase No Xfer Secure

TSC 80e

ONLY

PROG 2

PROG 3

PROG 1

Gen

Warm-up

Gen UV

Gen Freq

Gen Start

BT1

TB7

REAL TIME CLOCK BATTERY (TSC80e only)

Utility UV

Neutral

Delay

Utility Return

Gen

Cooldown

SYS OK

ENG STOP

TRANSFORMER

XFER UTIL

XFER GEN

LD ON GEN

LD ON UTIL

TB6

TB2-5

TB1

FIGURE 2

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

interface items:

2.2.1. TERMINAL BLOCKS

Terminal blocks are located on the PCB as follows:

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

WARNING

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TSC 80 TRANSFER SWITCH CONTROLLER

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.

TB2-6 transfer control terminal block for 115VAC control power and input/output

circuits.

TB7 low voltage (5Vdc) control inputs.

2.2.2. DIAGNOSTIC LED’S

The TSC 80 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 This LED flashes on and off at irregular intervals, which

indicates the microprocessor is functioning normally.

TRANSFER TO UTILITY This LED is illuminated whenever the TSC 80 is initiating a

signal to transfer to the Utility supply.

TRANSFER TO GEN This LED is illuminated whenever the TSC 80 is initiating a

signal to transfer to the Generator supply.

ENGINE STOP This LED is illuminated whenever the TSC 80 is initiating an

Engine STOP signal.

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