THOMSON TSC 80 - V2.2 User manual

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Telefax [phone] E-Mail: [e-mail] www.thomsontechnology.com
TSC 80
TRANSFER SWITCH CONTROLLER
INSTALLATION, OPERATING &
SERVICE MANUAL
Software Version 2.2
PM063 Rev 7 09/02/27

TSC 80 TRANSFER SWITCH CONTROLLER
PM063 Rev 7 09/02/27 Thomson Technology
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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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

TSC 80 TRANSFER SWITCH CONTROLLER
PM063 Rev 7 09/02/27 Thomson Technology
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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
1.0 04/11/19 Original version
1.1 05/05/10 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 Beta Test Software-Not released for production
1.3 05/11/05 Software updated to change some internal default timer settings
2.0 08/08/14 Software updated to incorporate TSC 80e Option
2.1 09/01/01 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
C
o
n
t
a
c
t
Thomson Technology, to obtain applicable instruction manuals. Soft copy of most current
version is available at www.thomsontechnology.com.
Rev 0 04/11/19 Original release
Rev 1 05/05/10 The following changes have been incorporated:
 Add changes for revised TSC 80 Software version 1.1.
 Add new Environmental Section
 Miscellaneous changes
Rev 2 05/12/15 Add changes for revised TSC 80 Software version 1.3.
Rev 3 08/08/01 Add changes for TC80e Option
Rev 4 08/08/18 Revised Default Settings for TSC 80E
Rev 5 09/01/01 Manual changed to dedicated TSC 80 manual (removed TSC 80E
references)

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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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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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208V
B
(O range)
(High Leg)
C
(Yellow)
A
(R ed)
N
(W hite)
PH A
(UA)
Automatic Transfer
Switch (Utility Supply)
PH B
(UB)
PH C
(UC)
Neural
(N)
120V 120V
240V 240V
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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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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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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FIGURE 1- TSC 80 Controller Lexan Faceplate

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2.2. PRINTED CIRCUIT BOARD
TB2-5
TRANSFORMER
10
9 8 7 6 5 4 3 2 1
1
11
28
TRANSFORMER
44
38 600V
480V
380V
240V
50HZ
1 Phase
No Xfer
Secure
Gen
Warm-up
Gen UV
Gen Freq Utility Return
Neutral
Delay
Utility UV
Gen Start Gen
Cooldown
TB1
TB7
JP5
SYS OK
XFER UTIL
XFER GEN
LD ON GEN
LD ON UTIL
ENG STOP
29
37
PROG 2
PROG 3
PROG 1
TB6
TSC 80e
ONLY
BT1
REAL TIME
CLOCK
BATTERY
(TSC80e only)
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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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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2.2.3. ADJUSTMENT POTENTIOMETERS
The TSC 80 controller utilizes eight adjustment potentiometers, which are mounted on
the printed circuit board as per FIGURE 2. They are used for adjustment of all time
delays, voltage and frequency setpoints. All potentiometers will be set to factory
default values. Refer to Section 4.0 (CONFIGURATION INSTRUCTIONS) for further
information.
2.2.4. CONFIGURATION JUMPERS
The TSC 80 controller utilizes eight Configuration Jumpers, which are mounted on the
printed circuit board as per FIGURE 2. They are used for configuration of main system
operating parameters such as voltage, frequency and phases. Refer to Section 4.0
(CONFIGURATION INSTRUCTIONS) for further information.
2.3. TSC 80 CONTROLLER FEATURES
The Thomson Technology TSC 80 Transfer Switch Controller utilizes the latest advancements
in microprocessor technology, printed circuit board assembly and software for control of
automatic transfer switches. The TSC 80 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 80 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 potentiometers, which requires no 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)

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• 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
• Local plant exercise initiate pushbutton & LED, door mounted
• Engine start contact (10A, 120/240VAC resistive max.)
• Load on utility auxiliary contact (Qty 1 only, 10A, 120/240VAC, Form C)
• Load on generator auxiliary contact (Qty 1 only, 10A, 120/240VAC, Form C)
• Transfer fail/forced transfer logic
• Automatic force transfer to alternate supply should load voltage become de-
energized
• 50 or 60Hz capable (115V control power)
• Remote Load Test/Peak Shave Input
2.4. APPLICATION INFORMATION
2.4.1. AC VOLTAGE SENSING INPUT
The TSC 80 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 80 / TSC 80e
1
2
3
25
26
24
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
1PT REQUIRED FOR TRANSFER SWITCH MECHANISM POWER
(MUST BE SIZED TO SUIT POWER REQUIREMENTS).
NOTE: UTILITY VOLTAGE SENSING AND
CONTROL POWER SHOWN ONLY.
BA C N
GRD
GRD
120
1
GRD
3Ø, 4W 208/380/480/600VAC DIRECT SENSING
VOLTAGE INPUTS
240VAC L-L, 120VAC L-N
NOTE: UTILITY VOLTAGE SENSING SHOWN ONLY.
TSC 80 / TSC 80e L2L1 N
1
2
3
10
25
24
GRD
GRD
26
NO CONNECTION
1Ø, 3W 120/240VAC DIRECT SENSING
1
2
3
25
26
24
NOTE: UTILITY VOLTAGE SENSING AND CONTROL POWER SHOWN ONLY.
BA C N
GRD
GRD
120V
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.
A
B C
N
3Ø, 4W 120/240V HIGH LEG DELTA DIRECT CONNECTION
TSC 80 / TSC 80e
SECONDARY PT VOLTAGE
120VAC L-L [NO NEUTRAL]
NOTE: ØB IS GROUNDED
TSC 80 / TSC 80e BA C
1
2
3
25
26
24
GRD
120
1
120
120
1PT REQUIRED FOR TRANSFER SWITCH MECHANISM POWER
(MUST BE SIZED TO SUIT POWER REQUIREMENTS).
NOTE: UTILITY VOLTAGE SENSING SHOWN ONLY.
GRD
GRD
38
43
3Ø, 3W DELTA PT's
FIGURE 3

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2.4.2. AC CONTROL POWER INPUT
The TSC 80 is factory supplied for 115VAC (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 80 control circuits and external control device
loads. The TSC 80 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 80 provides the following types of output circuits:
Engine Start Contact Isolated Form B contact (10A, 120VAC Resistive)
Load on Utility Isolated Form C contact (10A, 120VAC/250VAC
Resistive)
Load on Generator Isolated Form C contact (10A, 120VAC/250VAC
Resistive)
Transfer to Utility Output 120VAC, 10A (Resistive) powered output contact
Transfer to Generator Output 120VAC, 10A (Resistive) powered output contact
Interposing relays are required between the TSC 80 outputs and the end device if
loads exceed the output current rating.

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3. OPERATING INSTRUCTIONS
To operate the TSC 80 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 phase, an engine start delay circuit 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 (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 (70 - 95% nominal adjustable) the Engine Warm-up timer will be
initiated. Once 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.
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 position 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

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neutral delay timer (0-30 seconds adjustable) setting. Once the time delay expires, the
re-transfer sequence will be completed.
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 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 timer
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 80 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
The “TRANSFER SWITCH FAIL” feature can be disabled by
activating the “Service Entrance” Mode by jumpering terminal

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numbers 38 & 42. The TSC 80 controller will not verify that the
transfer mechanism has operated correctly.
3.1.2.4.TRANSFER FAIL DETECTION-NORMAL STEADY STATE
CONDITION (NON-TRANSFERRING)
i. Limit Switch Failure (i.e. open contact) - Transfer Fail Alarm is initiated
(Load on Source Flashing LED) after 9 second delay, and then a forced
transfer to the alternate source is initiated. Re-transfer back to the original
source will not occur until the Transfer Fail alarm condition is reset. Refer
to item 3.3 for Transfer Fail Fault Reset details.
ii. Loss of Load Voltage (<80VAC) (i.e. Power switching device Tripped
Condition) - Transfer Fail Alarm is initiated (Load Source Flashing LED)
after 5 second delay, then a forced transfer to the alternate source is
initiated. Re-transfer back to the original source will not occur until the
Transfer Fail alarm condition is reset. Refer to item 3.3 for Transfer Fail
Fault Reset details.
iii. Limit Switch Failure & Loss of Load Voltage <80VAC - Transfer Fail Alarm
is initiated (Load Source Flashing LED) after 11 second delay, then a
forced transfer to the alternate source is initiated. Re-transfer back to the
original source will not occur until the Transfer Fail alarm condition is reset.
Refer to item 3.3 for Transfer Fail Fault Reset details.
3.1.2.5.TRANSFER FAIL DETECTION - TRANSFERRING CONDITION
Transfer Source to Neutral – “NEUTRAL POSITION TIME” (10 seconds-
adjustable with SDM) starts timing as soon as a transfer to the alternate source
is initiated. During this period the ATS motor is energized and moves the
mechanism from the original source to neutral. The power to the motor will be
de-energized when either the “NEUTRAL POSITION TIME” times out or the
load voltage drops below 80VAC on all phases (whichever occurs first). Once
the ATS motor is de-energized, the Neutral Delay timer starts timing. Once the
Neutral Delay timer times out the motor re-energizes to continue the transfer
(see below). Note: Normally the load voltage will typically drop below the
setpoint within 1 second when the source power switching device opens and
therefore the “NEUTRAL POSITION TIME” never times out. The default setting
of this timer (10 seconds) is intentionally set long so that it will not pre-maturely
stop the ATS mechanism.