THOMSON TSC 900 Installation, Operating & 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
INSTALLATION, OPERATING &
SERVICE MANUAL
Part ID PM151 REV 5 16/04/19
TSC 900 TRANSFER SWITCH CONTROLLER
PM 151 REV 5 16/04/19 Thomson Power Systems
TSC 900 TRANSFER SWITCH CONTROLLER
PM 151 REV 5 16/04/19 Thomson Power Systems
TABLE OF CONTENTS
1. INTRODUCTION 1
1.1. PRODUCT REVISION HISTORY 1
1.2. GENERAL DESCRIPTION 2
2. INSTALLATION 2
2.1. GENERAL INFORMATION 3
2.2. NOTES TO INSTALLER 3
2.3. TSC 900 GHC MOUNTING 4
2.4. AC VOLTAGE SENSING INPUT 5
2.5. AC CURRENT SENSING INPUT 7
2.6. AC CONTROL POWER INPUT 8
2.7. AUXILIARY DC CONTROL POWER INPUT 8
2.8. PROGRAMMABLE INPUTS 8
2.9. OUTPUTS 8
2.10. EXTERNAL ATS CONTROL WIRING 8
2.11. REMOTE START CONTACT FIELD WIRING 9
2.12. COMMUNICATION CABLE INSTALLATION 10
2.13. DIELECTRIC TESTING 10
3. DESCRIPTION 11
3.1. GRAPHICAL HMI CONTROLLER (GHC) DISPLAY HARDWARE 12
3.2. SWITCH CONTROL UNIT (SCU) HARDWARE 13
3.3. ATS OPERATION MODE DESCRIPTIONS 15
3.4. AUTOMATIC SEQUENCE OF OPERATION 17
3.4.1. OPEN TRANSITION TRANSFER 17
3.4.2. CLOSED TRANSITION TRANSFER 17
3.4.3. DUAL SOURCE ATS 19
3.4.4. AUTOMATIC LOAD SHED OPERATION 22
3.4.5. TEST MODE 23
3.4.6. ABNORMAL SEQUENCE OF OPERATION 24
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3.5. GHC DISPLAY MAIN MENU PAGE DESCRIPTIONS 25
3.5.1. HOME PAGE 26
3.5.2. UTILITY METERING PAGE 27
3.5.3. GENERATOR METERING PAGE 27
3.5.4. LOAD METERING PAGE 28
3.5.5. ALARMS PAGE 28
3.5.6. ALARMS LOG PAGE 29
3.5.7. EVENTS LOG PAGE 31
3.5.8. SYNC PAGE 32
3.5.9. SCHEDULER PAGE 33
3.5.10. SETTINGS PAGE 33
3.5.11. SYSTEM PAGE 34
3.6. GHC DISPLAY SYSTEM SUBMENU PAGE DESCRIPTIONS 35
3.6.1. IMPORT/EXPORT DATA 35
3.6.2. DATE / TIME SETUP 35
3.6.3. MANAGE USERS 36
3.6.4. SYSTEM INFORMATION 36
3.6.5. INPUT MAPPING 37
3.6.6. OUTPUT MAPPING 37
3.6.7. LOGS 38
3.6.8. COMMUNICATION STATUS 38
3.6.9. MIMIC BUS CUSTOMIZATION 39
3.6.10. FIRMWARE UPDATES 39
3.6.11. GHC HEALTH 39
4. OPERATING INSTRUCTIONS 40
4.1. GHC SCREEN PAGE NAVIGATION 40
4.2. HELP INFORMATION 40
4.3. ON LOAD TEST INSTRUCTIONS (UTILITY POWER FAIL SIMULATION) 41
4.4. OFF LOAD TEST INSTRUCTIONS (GENERATOR NO LOAD TEST) 42
4.5. TIMED TEST INSTRUCTION 43
4.6. OPEN/CLOSED TRANSITION TRANSFER OPERATION 45
4.6.1. OPEN TRANSITION IN-SYNC TRANSFER OPERATION (MODEL X) 46
4.6.2. CLOSED TRANSITION OPERATION (FAST TRANSFER MODEL 3) 46
4.6.3. CLOSED TRANSITION OPERATION (SOFT-LOAD TRANSFER MODEL 4) 47
4.7. DUAL SOURCE ATS OPERATION 50
4.7.1. DUAL SOURCE - CHANGING PREFERRED UNITS (GHC CONTROL) 51
4.8. TRANSFER FAIL ALARM RESET 52
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4.9. TIMER BYPASS 52
4.10. MANUAL UTILITY RETRANSFER CONTROL 53
4.11. SERVICE DISCONNECT MODE 53
4.12. PHASE UNBALANCE PROTECTION ALARM RESET 54
4.13. TRANSFER HALTED ALARM RESET 55
4.14. ABNORMAL SOURCE ALERT 56
5. PROGRAMMING INSTRUCTIONS 57
5.1. PASSWORD SECURITY DESCRIPTION (USERS ADMIN) 57
5.2. USER LOGIN PROCEDURE 58
5.3. ADMINISTRATOR PASSWORD MANAGEMENT PROCEDURE 59
5.4. SYSTEM TIME/DATE ADJUSTMENT 60
5.5. VOLTAGE CHANGE PROCEDURE 61
5.6. REMOTE COMMUNICATION SETUP 63
5.7. EXERCISE TIMER SETUP 63
5.7.1. ADDING NEW EXERCISE SCHEDULE EVENT 63
5.7.2. EDITING EXISTING EXERCISE SCHEDULE EVENT 64
5.8. PROGRAMMABLE DIGITAL INPUT MAPPING 65
5.8.1. TS 870 STANDARD/SERVICE ENTRANCE INPUT DEFAULTS: 65
5.8.2. TS 870 DUAL SOURCE INPUT DEFAULTS: 65
5.8.3. TS 880 (ICS) STANDARD/SERVICE ENTRANCE INPUT DEFAULTS: 66
5.8.4. TS 880 (ICS) CLOSED TRANSITION INPUT DEFAULTS: 66
5.8.5. PROGRAMMABLE INPUT FUNCTION LIST 67
5.8.6. PROGRAMMABLE INPUT FUNCTION MAPPING 69
5.8.7. PROGRAMMABLE INPUT USER DEFINED CUSTOM NAME MAPPING 70
5.9. PROGRAMMABLE OUTPUT MAPPING 72
5.9.1. TS 870 STANDARD/SERVICE ENTRANCE OUTPUT DEFAULTS: 72
5.9.2. TS 870 DUAL SOURCE OUTPUT DEFAULTS: 72
5.9.3. TS 880 (ICS) STANDARD/SERVICE ENTRANCE OUTPUT DEFAULTS: 72
5.9.4. TS 880 (ICS) CLOSED TRANSITION OUTPUT DEFAULTS: 72
5.9.5. PROGRAMMABLE OUTPUT FUNCTION LIST 73
5.9.6. PROGRAMMABLE OUTPUT FUNCTION MAPPING 76
5.10. SYSTEM SETTINGS 77
5.10.1. SYSTEM PHASES 78
5.10.2. SYSTEM VOLTAGE 78
5.10.3. SYSTEM FREQUENCY 78
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5.10.4. PHASE ROTATION REVERSED 78
5.10.5. RATED GENERATOR POWER 78
5.10.6. CT RATIO (CURRENT TRANSFORMER) 78
5.10.7. PT RATIO (POTENTIAL TRANSFORMER) 78
5.10.8. LOAD NAME 79
5.10.9. SOURCE 1 (UTILITY) NAME 79
5.10.10. SOURCE 2 (GEN) NAME 79
5.10.11. APPLICATION MODEL 79
5.10.12. SWITCH OPERATION 79
5.10.13. SWITCH MODEL 79
5.11. OPTION SETTINGS 79
5.11.1. SRC 2 (GEN) COMMIT TO TRANSFER 79
5.11.2. ENABLE LOAD SHED ON UNDER FREQUENCY 80
5.11.3. ENABLE LOAD SHED ON OVER POWER 80
5.11.4. HALT OPERATION ON PHASE REVERSAL 80
5.11.5. MANUAL SRC 1 (UTILITY) RETRANSFER CONTROL 80
5.11.6. FORCE TRANSFER 81
5.11.7. GHC SLEEP MODE TIMEOUT 81
5.11.8. LOAD POWER METERING 81
5.11.9. MODBUS RTU 81
5.11.10. MODBUS TCP/IP 82
5.11.11. ENABLE SECURITY BYPASS 82
5.11.12. ENABLE NEUTRAL DELAY BYPASS 82
5.11.13. ENABLE TRANSFERS TO SRC 1 (UTILITY) 82
5.11.14. ENABLE TRANSFERS TO SRC 2 (GENERATOR) 83
5.11.15. ENABLE FAIL TO AUTO SYNC ALARM 83
5.11.16. ENABLE HALT TRANSFER ON FAIL TO EXTERNAL SYNC CHECK 83
5.11.17. ENABLE CLOSED TRANSITION TRANSFER (CTTS MODEL 3 & 4) 83
5.11.18. REVERT TO OPEN TRANSITION 84
5.11.19. ENABLE FAIL TO UNLOAD ALARM (CTTS MODEL 4) 84
5.11.20. ENABLE EXTENDED PARALLEL MODE (CTTS MODEL 4) 85
5.11.21. ENABLE SOFT-LOAD TRANSFER (CTTS MODEL 4) 85
5.11.22. ENABLE START OF MULTIPLE GENS WHEN RESUMING FROM STANDBY 85
5.11.23. PREFERRED SOURCE ALTERNATION INTERVAL 86
5.11.24. TRIP UTILITY (SRC 1) WHEN CLOSED TRANSITION INHIBIT ACTIVATED 86
5.11.25. CURRENT METERING 86
5.11.26. ENABLE OPEN TRANSITION IN-SYNC TRANSFER (ATS MODEL X) 86
5.12. DELAY SETTINGS 87
5.12.1. UTILITY (SRC 1) RETURN DELAY 87
5.12.2. GEN (SRC 2) COOL DOWN DELAY 87
5.12.3. GEN (SRC 2) START DELAY 87
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5.12.4. GEN (SRC 2) WARM UP DELAY 87
5.12.5. TRANSFER NEUTRAL DELAY 88
5.12.6. TRANSFER PRE DELAY (LDC) 88
5.12.7. TRANSFER POST DELAY (LDC) 88
5.12.8. SRC 2 (GEN) GEN COMMIT TO TRANSFER DELAY 88
5.12.9. TRANSFER FAIL DELAY 88
5.12.10. TRANSFER MAX ERROR CONDITION DELAY 88
5.12.11. GEN (SRC 2) FAILED TO START DELAY 89
5.12.12. DISCONNECTION RESUME TIME 89
5.12.13. TRIP RETRY ON/OFF PULSE TIME (SRC1&2) 89
5.12.14. TRIP RETRY DURATION TIMER (SRC1&2) 89
5.12.15. CLOSE RETRY ON/OFF PULSE TIME (SRC1&2) 89
5.12.16. CLOSE RETRY DURATION TIMER (SRC1&2) 90
5.12.17. TIMER GUARD DELAY 90
5.12.18. FIND NEUTRAL DELAY 90
5.12.19. RETURN TO PREFERRED SOURCE DELAY 91
5.12.20. WAIT FOR PREFERRED SOURCE DELAY 91
5.12.21. TRANSFER FROM PREFERRED SOURCE DELAY 91
5.13. UTILITY/GEN SET POINTS (VOLTAGE/FREQUENCY) 91
5.13.1. UNDER VOLTAGE DELAY (DROPOUT) 92
5.13.2. UNDER VOLTAGE DROPOUT 92
5.13.3. UNDER VOLTAGE PICKUP 92
5.13.4. OVER VOLTAGE DELAY (PICKUP) 92
5.13.5. OVER VOLTAGE DROPOUT 92
5.13.6. OVER VOLTAGE PICKUP 92
5.13.7. PHASE UNBALANCED VOLTAGE LATCH 92
5.13.8. PHASE UNBALANCE DELAY (PICKUP) 93
5.13.9. PHASE UNBALANCE DROPOUT 93
5.13.10. PHASE UNBALANCE PICK UP 93
5.13.11. UNDER FREQUENCY DELAY (DROPOUT) 93
5.13.12. UNDER FREQUENCY DROPOUT 93
5.13.13. UNDER FREQUENCY PICKUP 94
5.13.14. OVER FREQUENCY DELAY (PICKUP) 94
5.13.15. OVER FREQUENCY DROPOUT 94
5.13.16. OVER FREQUENCY PICKUP 94
5.13.17. VOLTAGE SOURCE BLACKOUT DELAY (DROPOUT) 94
5.13.18. VOLTAGE SOURCE BLACKOUT DROPOUT 94
5.13.19. VOLTAGE SOURCE BLACKOUT PICKUP 94
5.13.20. VOLTAGE ROTATION REVERSAL DELAY (PICKUP) 95
5.13.21. VOLTAGE ROTATION REVERSAL DROP OUT 95
5.13.22. VOLTAGE ROTATION REVERSAL PICK UP 95
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5.14. LOAD VOLTAGE SET POINTS 95
5.14.1. LOAD VOLTAGE BLACKOUT DELAY (DROPOUT) 95
5.14.2. LOAD VOLTAGE BLACKOUT DROPOUT 95
5.14.3. LOAD VOLTAGE BLACKOUT PICKUP 95
5.15. LOAD SHED FREQUENCY & POWER SET POINTS 96
5.15.1. LOAD SHED INITIATE DELAY 96
5.15.2. LOAD SHED UNSHED DELAY 96
5.15.3. LOAD SHED FREQUENCY DELAY (PICKUP) 97
5.15.4. LOAD SHED FREQUENCY PICK UP 97
5.15.5. LOAD SHED FREQUENCY DROP OUT 97
5.15.6. LOAD SHED POWER (kW) DELAY (PICKUP) 97
5.15.7. LOAD SHED POWER (kW) DROP OUT 97
5.15.8. LOAD SHED POWER (kW) PICK UP 97
5.16. IN-SYNC TRANSFER SET POINTS 97
5.16.1. IN-SYNC WAIT DELAY 97
5.16.2. EXTERNAL SYNC CHECK WAIT DELAY 98
5.16.3. FAIL TO UNLOAD TIMER (CTTS MODEL 4) 98
5.16.4. CLOSED TRANSITION MAX OVERLAP TIMER 98
5.16.5. SOURCE FREQUENCY DIFFERENTIAL HIGHER THRESHOLD 98
5.16.6. SOURCE FREQUENCY DIFFERENTIAL LOWER THRESHOLD 99
5.16.7. SOURCE VOLTAGE DIFFERENTIAL HIGHER THRESHOLD 99
5.16.8. SOURCE VOLTAGE DIFFERENTIAL LOWER THRESHOLD 99
5.16.9. TRANSFER SWITCH MECHANISM OPERATION TIME 99
6. FACTORY DEFAULT PROGRAMMING 100
7. TSC 900 TYPICAL CONNECTION DIAGRAM 104
8. TSC 900 WIRING PIN CONNECTIONS 105
9. TROUBLESHOOTING 106
10. REPLACEMENT PARTS 110
11. PRODUCT RETURN POLICY 111
12. NOTES 112
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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.
SCU Firmware Version
621, 15/04/07
Original Release
867, 15/10/03
Add Closed Transition Transfer Capability, Misc.
Feature Enhancements & Bug Fixes
888, 15/10/28
Add Dual Source Capability, Misc. Feature
Enhancements & Bug Fixes
902, 15/11/18
Add Remote Load Dump Control (RLDC) feature
capability
GHC Firmware Version
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
1.1.0.16017 15/10/30
Add Dual Source Capability, Misc. Feature
Enhancements & Bug Fixes
1.1.5805.19916 15/11/18
Add Remote Load Dump Control (RLDC) feature
capability
1.1.5952.22994 16/04/19
Update Alarm Tag Names, add GHC Firmware
Update, Misc. Feature Enhancements & Bug Fixes
Operating & Service Manual Version
Rev 0 15/04/07
Original release
Rev 1 15/10/08
Add Closed Transition Transfer Capability, Misc.
Feature Enhancements & Bug Fixes
Rev 2 15/11/11
Add Dual Source Capability, Misc. Feature
Enhancements & Bug Fixes
Rev 3 15/11/24
Add Remote Load Dump Control (RLDC) Feature
capability
Rev 4 16/01/15
Update Alarm Tag Names, add GHC Firmware
Update, Add TSC 900 Faceplate mounting
information
Rev 5 16/04/19
Miscellaneous minor manual revisions
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.
TSC 900 TRANSFER SWITCH CONTROLLER
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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.
2. INSTALLATION
CAUTION!!!
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.
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.
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2.1. GENERAL INFORMATION
NOTE:
Installations should be done in accordance
with all applicable electrical regulation
codes as required.
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 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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2.3. TSC 900 GHC MOUNTING
When the TSC 900 display (GHC) is supplied as part of a Thomson Power System automatic
transfer switch, the GHC is mounted on the ATS door with PEM studs as part of the door design.
When the TSC 900 GHC is supplied loose for door mounting, it can be supplied with a door
mounting faceplate with Lexan overlay (PART No’s 014222, 014221) which requires a
rectangular door cut-out and mounting holes to be drilled as per the following drawings.
GHC
SCU
(Optional
Mounting)
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2.4. 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) can be 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:
Refer to Section 5.10.2 for system voltage programing instructions.
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Voltage sensing connections for the most common applications are shown in the following
diagrams.
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2.5. 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.
WARNING
Do not unplug any current transformer inputs while
energized as severe high voltages can develop which may
cause personal injury or death.
Current sensing connections for the most common applications are shown in the following
diagrams.
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2.6. 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 typically requires approximately 12VA AC power for internal control circuits but may
draw up to 30VA dependent upon external loads connected. 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.
2.7. 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 25W. The 24VDC power must be from a regulated/filtered DC supply with
maximum +-10% voltage range.
2.8. 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.
2.9. OUTPUTS
The TSC 900 provides the following types of output circuits:
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 (SRC1) Supply
Qty 1
120VAC1, 10A (Resistive) powered output contact
Close to Gen (SRC2) Supply
Qty 1
120VAC1, 10A (Resistive) powered output contact
Trip Utility (SRC1) Supply
Qty 1
120VAC1, 10A (Resistive) powered output contact
Trip Gen (SRC2) Supply
Qty 1
120VAC1, 10A (Resistive) powered output contact
1
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.
2.10. 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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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 microprocessor 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.
1
For distances exceeding 1000ft. (300m) consult Thomson Power Systems
2.11. 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.
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2.12. 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:
• 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.
2.13. 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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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 3.0A-to-micro-B high speed communication cable which includes DC
power.
USB 3.0 Cable
GHC
SCU
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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 a plugin 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
1
5
6
7
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3.2. SWITCH CONTROL UNIT (SCU) HARDWARE
The Switch Control Unit internal PCB is shown in the following diagram:
2 1 4
3
5
8
9
11
12
13
14
15
16
6
10
17
18
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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
12
10
9
7
11
8
6
18
1 2 3 4 5
16
15
14
13
17
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3.3. ATS OPERATION MODE DESCRIPTIONS
The TSC 900 has the following main operating modes as described per the table below:
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 failure
1
Engine will stop if it was previously
running
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 it 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 it 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
1
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 close 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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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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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.
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 transfer to generator supply signal will be
removed (contact opening), 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 position delay circuit can be employed which 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 setting, once the time delay expires, the retransfer 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.
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
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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.
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 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” re-transfer 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.
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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3.4.3. DUAL SOURCE ATS
ATS may be supplied with the following 3 types of optional Dual Source system
configurations:
• DU - Dual Utility ATS: Used for systems consisting of one ATS connected to two
utilities with at least one source continually energized to the ATS. ATS will
automatically switch to the alternate source upon failure of the preferred source.
• DPG - Dual Prime Gen ATS: Used for systems consisting of one ATS connected to
two generators with one generator continually energized to the ATS. ATS will
automatically switch to the alternate generator upon failure of the preferred source.
• DSG - Dual Standby Gen ATS (Slave ATS): Used for systems consisting of two
ATS's in a Master/Slave Configuration. Refer to the following diagram. Only the
"Slave" ATS is to be ordered and configured with the “DSG” option. The Master ATS
is to be ordered as a standard ATS. The "Slave" ATS will be connected to two
generators which are normally de-energized and are signaled to start from the Master
ATS.
3.4.3.1. DUAL UTILITY ATS
A Dual Utility application allows an operator to select which source is “preferred”
(i.e. Either source may be selected as Preferred), therefore, the alternate source
will act as the standby source. The “PREFERRED” selected source will
continuously operate on load. The non-selected preferred source (standby) will
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remain off load. The standby source will automatically transfer on load should
the “Preferred” source fail once the “Transfer From Preferred Source Delay”
timer expires. When the “Preferred” selected source is returned to normal
operating status, the load will automatically retransfer back to the “Preferred”
selected source once the “Return to Preferred Source Delay” timer expires. If the
PREFERRED SOURCE selector switch is turned to the non-operating source,
the load will automatically transfer to this new “Preferred” source once the
“Transfer From Preferred Source Delay” timer expires.
3.4.3.2. DUAL PRIME GENERATOR ATS
A Dual Prime Generator application allows an operator to select which generator
is “preferred” (i.e. Either generator may be selected as Preferred), therefore, the
alternate generator will act as the standby source. The “PREFERRED” selected
generator will continuously operate on load with an engine start signal
maintained. The non-selected preferred generator (standby) will remain off load.
The standby generator will be signaled to automatically start the engine and
transfer on load (following its warm up delay period) should the “Preferred”
generator fail once the “Transfer From Preferred Source Delay” timer expires.
When the “Preferred” selected generator is returned to normal operating status,
the load will automatically retransfer back to the “Preferred” selected generator
once the “Return to Preferred Source Delay” timer expires. If the PREFERRED
SOURCE selector switch is turned to the non-operating generator, the load will
automatically transfer to this new “Preferred” generator once the “Transfer From
Preferred Source Delay” timer expires. The originally selected “Preferred” unit
will continue to operate for its cool down period then stop. An automatic Engine
Run-Hour balancing program is provided for configuration/use in the Dual Prime
Mode. When enabled it will automatically start/stop and transfer each engine
(Genset) on/off load to try to balance engine running hours as stored in memory.
Refer to programming section 5 for further details. Should a “trouble alarm” occur
on the operating “Preferred” source, the ATS will automatically transfer to the
“Standby Source until the trouble alarm condition is reset. Note: the “trouble
alarm” operation feature requires a digital programmable inputs (i.e. Default
inputs Source 1 –IP13, Source 2 –IP14) to be pre-configured and wired to the
appropriate engine-generator set controller.
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3.4.3.3. DUAL STANDBY GENERATOR ATS
Under normal Utility Power operation, power to the load will be fed from the
Master ATS via closed Utility power switching device. The Dual Standby (“Slave”)
ATS remains de-energized with both generators stopped. Should the utility
power fail, the Master ATS will send a common gen start signal to the Dual
Standby ATS. The Dual Standby ATS will then send a start signal to one or both
Gensets (programmable) to start. The Dual Standby ATS will transfer to the
"Preferred” selected generator position. Once generator voltage is established
back to the Master ATS, the load will automatically transfer onto the operating
generator. The “Standby” Gen will automatically stop if selected to do so. The
"Preferred” selected generator will be continuously connected to the load via the
Master ATS until Utility Power is re-established. Should the "Preferred” generator
fail while on load, the "standby" selected generator set will automatically start and
the load will be automatically transferred to the "standby" generator. When the
utility power returns to normal, the Master ATS will transfer the load back to the
utility supply and will send a signal to the Dual Standby ATS to stop the operating
generator. The operating generator unit will continue to run for its cool down
period then stop. An automatic Engine Run-Hour balancing program is provided
for configuration/use in the Dual Prime Mode. When enabled it will automatically
start/stop and transfer each engine (Genset) on/off load to try to balance engine
running hours as stored in memory. Refer to programming section 5 for further
details. Note: the “trouble alarm” operation feature requires a digital
programmable inputs (i.e. Default inputs Source 1 –IP13, Source 2 –IP14) to be
pre-configured and wired to the appropriate engine-generator set controller.
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3.4.4. 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 a utility power failure occurs and the ATS transfers to the
generator supply, the Load Shed circuit is automatically initiated for a pre-programmed
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. The automatic
sequence of operation is further described as per the following state diagram.
Note: to disable Load Shed feature, Load Shed Initiate and Reset timers must be set to
zero. Refer to Section 5.15 for programming instructions
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