THOMSON marathon TS 910 Series User manual

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TS 910
AUTOMATIC TRANSFER SWITCHES
OWNERS MANUAL
INSTALLATION, OPERATING &
SERVICE
PM140 Rev 0 12/02/09

TS 910 TRANSFER SWITCH
PM140 REV 0 12/02/09 1Thomson Technology
TABLE OF CONTENTS
1. PRODUCT REVISION HISTORY 1
2. EQUIPMENT STORAGE 1
3. NOTES TO INSTALLER 2
3.1. APPLICATION 2
3.2. CHECK EQUIPMENT DELIVERY 2
3.3. CHECK LINE VOLTAGE/AMPERAGE 2
3.4. INSTALLATION REQUIREMENTS 3
3.5. DIELECTRIC TESTING 5
4. GENERAL DESCRIPTION 6
4.1. PRODUCT MODEL CODE 6
4.2. TS 910 OPTIONAL ACCESSORIES 7
4.3. TYPICAL COMMISSIONING PROCEDURES 7
5. GENERAL THEORY OF OPERATION 8
5.1. AUTOMATIC SEQUENCE OF OPERATION 8
5.2. SERVICE ENTRANCE AUTOMATIC TRANSFER SWITCH OPERATION 8
6. OVER CURRENT PROTECTION 11
6.1. STANDARD TS 910 AUTOMATIC TRANSFER SWITCH 11
6.2. SERVICE ENTRANCE RATED TS 910 AUTOMATIC TRANSFER SWITCH 11
7. GENERAL NOTES ON SERVICING TRANSFER SWITCH MECHANISM 11
8. TRANSFER SWITCH MECHANISM OPERATION 12
8.1. AUTOMATIC OPERATION 12
8.2. MANUAL OPERATION 12
9. RECOMMENDED MAINTENANCE 15
10. FRONT INTERIOR VIEW (2 POLE 100A STANDARD ATS) 16

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11. FRONT INTERIOR VIEW (2 POLE 100A SERVICE ENTRANCE ATS) 17
12. FRONT INTERIOR VIEW (2 POLE 200A STANDARD ATS) 18
13. FRONT INTERIOR VIEW (2 POLE 200A SERVICE ENTRANCE ATS) 19
14. FRONT INTERIOR VIEW (2 POLE 400A STANDARD ATS) 20
15. FRONT INTERIOR VIEW (2 POLE 400A SERVICE ENTRANCE ATS) 21
16. ENCLOSURE DIMENSIONS/CABLE TERMINALS 22
17. REQUIREMENTS FOR UPSTREAM CIRCUIT PROTECTIVE DEVICES 22
17.1. TRANSFER SWITCH WITHSTAND CURRENT RATINGS 22
17.2. 100A TRANSFER SWITCH UPSTREAM CIRCUIT PROTECTIVE DEVICES 23
17.3. 200A TRANSFER SWITCH UPSTREAM CIRCUIT PROTECTIVE DEVICES 24
17.4. 400A TRANSFER SWITCH UPSTREAM CIRCUIT PROTECTIVE DEVICES 25
17.5. INTERRUPTING CAPACITY CURRENT RATINGS (ALL SERVICE ENTRANCE
RATED MODELS) 25
18. TSC 9 TRANSFER SWITCH CONTROLLER 26
18.1. DESCRIPTION 26
18.2. ELECTROSTATIC DISCHARGE PRECAUTIONS 27
18.3. DIELECTRIC TESTING 27
18.4. TSC 9 FACEPLATE 28
18.5. TSC 9 FACEPLATE LIGHTS AND PUSHBUTTON OPERATION 29
18.6. TSC 9 PRINTED CIRCUIT BOARD 30
18.7. TSC 9 OPERATING INSTRUCTIONS 34
18.8. TSC 9 OPERATING MODE DESCRIPTIONS 35
18.9. TEST MODES 37
18.10. TRANSFER FAIL FAULT RESET 39
18.11. LAMP TEST 39
18.12. TIMER BYPASS 40
18.13. TSC 9 VOLTAGE SENSING 40

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18.14. TSC 9 GENERATOR FREQUENCY SENSING 40
18.15. TSC 9 CONFIGURATION INSTRUCTIONS 41
18.16. LOAD SHED 45
19. TS 910 SCHEMATIC DIAGRAM 47
20. TROUBLESHOOTING 48
21. REPLACEMENT PARTS 49
22. PRODUCT RETURN POLICY 50
23. NOTES 51
APPENDIX A – TYPICAL AUTOMATIC TRANSFER SWITCH COMMISSIONING
PRIOCEDURES 52
a) Pre-Energization Checks 52
b) Equipment Energization 53

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1. PRODUCT REVISION HISTORY
The following information provides an historical summary of changes made to this product since the
original release.
Owners Manual Version
Rev 0 12/02/09 Original release.
Contact Thomson Technology, to obtain applicable instruction manuals or if in doubt about
any matter relating to installation, operation or maintenance. Soft copy of the most current
version is available at www.thomsontechnology.com.
NOTE: All information contained in this manual is for reference only and is subject
to change without notice.
2. EQUIPMENT STORAGE
The following procedures are required for correct storage of the transfer switch prior to installation.
CAUTION!!!
Failure to store equipment under the specified environmental conditions may cause
equipment damage and void warranty.
The transfer switch shall be stored in an environment with a temperature range not exceeding -4°to
+158° Fahrenheit (-20° to +70° Celsius) and a humidity range not exceeding 5%-95% non-
condensing. Before storing, unpack sufficiently to check for concealed damage. If concealed
damage is found, notify the ATS supplier and the Carrier immediately. Repack the transfer switch
with the original packing material (or equivalent). Protect from physical damage. Do not stack. Store
indoors in a clean, dry, well ventilated area free of corrosive agents including fumes, salt and
concrete/cement dust. Apply heat as necessary to prevent condensation.

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3. NOTES TO INSTALLER
DANGER!!!!
Arc Flash and Shock Hazard. Will cause severe injury or death.
Do not open equipment until ALL power sources are disconnected
This equipment must be installed and serviced only by qualified electrical
personnel utilizing safe work practices and appropriate Personal Protective
Equipment (PPE). Failure to do so may cause personal injury or death
3.1. APPLICATION
The TS 910 Transfer Switch is designed and is Listed by Underwriters Laboratories (UL) to
Safety Standard UL 1008 for Transfer Switches for Optional Standby applications only. This
product is not intended for installation or operation on legally required standby
applications for emergency power systems as defined by the National Electrical Code.
3.2. CHECK EQUIPMENT DELIVERY
Upon delivery of the transfer switch, remove the product packaging and verify the product
has not been damaged.
WARNING: Damaged Transfer Switch equipment: Do not install or operate the transfer
switch if it appears damaged. Failure to follow these instructions can result in death,
serious injury, or equipment damage.
Check that the model number printed on the inside cover of the transfer switch is the same
as on the delivery note corresponding to the purchase order.
3.3. CHECK LINE VOLTAGE/AMPERAGE
The transfer Switch is designed for a maximum voltage of 120/240V, Single Phase 3 wire
with neutral. Verify the line voltage and amperage of the transfer switch matches the site
requirements. Note: The transfer switch can be configured for operation on 208V sources

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by way of configuration jumper. Refer to Section 18.15 CONFIGURATION JUMPERS of
this manual for further information.
WARNING: Do not install the transfer switch if either voltage or amperage does not match.
Failure to follow these instructions can result in death, serious injury, or equipment
damage.
3.4. INSTALLATION REQUIREMENTS
Before installing the transfer switch, review the following requirements:
3.4.1. Installation Codes/Permits and ATS Sizing
Suitable permits are typically required by local jurisdictions having authority prior to
installing standby generator sets and automatic transfer switches. Per NEC Article
702, Automatic transfer switches shall be sized for either a) entire load whole house,
load calculation per NEC 220, or b) Pre-selected “EM” panel(s) of load being served
or optional standby panel and transfer switch, or c) automatic load shedding feature
to reduce total load imposed on the generator, not to exceed the capacity of the
generator. The TS 910 transfer switch has automatic load shedding capabilities built-
in when load shedding control contact is connected. Refer to Load Shedding section
of this manual for further details.
3.4.2. Installation Location
The standard TS 910 transfer switch is designed for indoor wall mounting. For
applications requiring outdoor wall mounting, a NEMA 3R door kit is optionally
available. The transfer switch must be installed in an environment where the
temperature range is within +5° to +122° Fahrenheit (-15° to +50° Celsius) and
humidity range not exceeding 5%-95% non-condensing.
3.4.3. Power Cabling
All power cabling entering/exiting the enclosure must be installed in suitably sized
conduit per NEC requirements. Ampacity, type and voltage rating of current carrying
conductors must also comply with NEC requirements and local jurisdictions having
authority.
Refer to Section 16 ENCLOSURE DIMENSIONS/CABLE TERMINALS of this
manual for further details.

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3.4.4. Control Wiring
All control wiring for engine start, load shed, alarm and remote test must be installed
in separate conduits from all power cabling and must utilize suitably sized conduits
per NEC requirements. All control wiring shall be sized for minimum #14 AWG.
Control wiring type and voltage rating must also comply with NEC requirements and
local jurisdictions having authority.
3.4.5. Generator Set Automatic Operation
The TS 910 transfer switch operates in conjunction with any generator set with
remote automatic starting capabilities utilizing a 2 wire, remote start control contact
input. A dry contact is provided for remote generator starting control (contact closes
to start generator and opens to stop generator). Refer to Section 18.6.1.1 Customer
Interface Control Terminal Block of this manual for further details.
3.4.6. Upstream Overcurrent Protection (Non-Service Entrance Rated TS
910)
Non-Service Entrance Rated TS 910 transfer switch models do not contain any
integral over current protection and require upstream over current protection devices
for both Utility and Generator sources. The standard TS 910 is rated for 100%
continuous loading of all load types. Refer to Section 17 REQUIREMENTS FOR
UPSTREAM CIRCUIT PROTECTIVE DEVICES of this manual for further details.
3.4.7. Upstream Overcurrent Protection (Service Entrance Rated TS 910)
Service Entrance rated TS 910 transfer switch models contain integral over current
protection for the Utility source as standard. Service Entrance rated TS 910 transfer
switches do not contain any integral over current protection for the generator source
and requires upstream generator source over current protection. The Service
Entrance rated TS 910 is rated for 80% maximum continuous loading of all load
types. Refer to Section 17 REQUIREMENTS FOR UPSTREAM CIRCUIT
PROTECTIVE DEVICES of this manual for further details.
3.4.8. Withstand/Interrupting Current Ratings
Non-Service Entrance Rated TS 910 can withstand a maximum short circuit fault
current of 10kA (RMS, Symmetrical) @240V (100A and 200A Models) and 25kA
@240V 400A models when used with specific type/model of upstream circuit breaker.
Service Entrance rated TS 910 can interrupt a maximum short circuit fault on the

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utility source of 10kA (RMS, Symmetrical) @240V (100A and 200A Models) and
25kA @240V 400A models when used with specific type/model of upstream circuit
breaker. Refer to Section 17 REQUIREMENTS FOR UPSTREAM CIRCUIT
PROTECTIVE DEVICES of this manual for further details.
WARNING: Do not install the transfer switch on systems with higher available short
circuit current levels than listed under section “Withstand/Interrupting Current
Ratings” shown above. Failure to follow these instructions can result in death,
serious injury, or equipment damage.
3.5. DIELECTRIC TESTING
Do not perform any high voltage dielectric testing on the transfer switch with the TSC
9 controller connected into the circuit as serious damage will occur to the controller.
The control circuit isolation plug connected to the TSC 9 must be removed if high
voltage dielectric testing is performed on the transfer switch.

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4. GENERAL DESCRIPTION
TS 910 Automatic Transfer Switches employ a power contactor switching unit with a microprocessor
based controller to automatically start a generator and transfer system load to a generator supply in
the event of a utility supply failure. System load is automatically re-transferred back to the utility
supply following restoration of the utility power source to within normal operating limits. All load
transfer sequences are “Open Transition” (i.e. “break-before-make”) utilizing an in-phase transfer
detection control sequence.
The TS 910 series transfer switches use a type TSC 9 microprocessor based controller. All
necessary control functions for fully automatic operation are provided by the TSC 9 transfer
controller. The TSC 9 controller is mounted inside the transfer switch enclosure and operating
status is provided via LED indicators that are visible though a front panel opening on NEMA 1 rated
enclosures. For detailed information on the TSC 9 Transfer Switch controller, refer to Section 18 of
this manual.
The standard TS 910 series Automatic Transfer Switch is rated for 100% system load and requires
upstream over current protection.
Service Entrance Rated TS 910 Automatic Transfer Switch models are supplied with a utility supply
circuit breaker with over current protection. Refer to Section 17 of this manual for detailed
information on over current protection.
4.1. PRODUCT MODEL CODE
The type of TS 910 series transfer switch supplied is identified by way of a 11 digit product
code which appears on the equipment rating plate (MODEL) on the inside of the door of the
transfer switch. The model code structure is as follows:
Model Number Amperage Voltage*
Standard
ATS
Service
Entrance
Rated ATS 2 Pole
3 w ire w ith
Neutral 50/60Hz
Nema 1
Enclosure
TS912A0100A
100A 120/240V
TS912A0100B
100A 120/240V
TS912A0200A
200A 120/240V
TS912A0200B
200A 120/240V
120/240V
TS912A0400A
400A 120/240V
TS912A0400B
400A 120/240V
*Configurable for 120/208V System Voltages

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4.2. TS 910 OPTIONAL ACCESSORIES
The following optional accessories may be ordered as field installable kits.
Model Code Description
TS910-HTR Enclosure Heater, 120VAC Fused, supplied from ATS
Load Bus
TS910-SPD1PH Surge Protective Device, Class 1, 120/240V connected
to Load Bus
TS910-KWLS1PH2 kW Load Shed Control output contact, Single Stage, 0-
200A Current Transformers connected to ATS Load Bus
TS910-KWLS1PH4 kW Load Shed Control output contact, Single Stage, 0-
400A Current Transformers connected to ATS Load Bus
TS910-WMS Wireless Remote Alarm Messaging Module
TS910-N3R100A
TS910-N3R100B
TS910-N3R200A
TS910-N3R200B
TS910-N3R400A
TS910-N3R400B
NEMA 3R Door, External Door Mountable to NEMA 1
ATS Enclosure (Specify matching ATS model number)
Additional information on TS 910 optional accessories can be obtained from our
Website (www.thomsontechnology.com ).
4.3. TYPICAL COMMISSIONING PROCEDURES
CAUTION:
Commissioning procedures must be performed by qualified
personnel only.
Note: The TYPICAL AUTOMATIC TRANSFER SWITCH COMMISSIONING
PROCEDURES MODEL SERIES TS 910 (attached as “Appendix A”) is provided for
general information only pertaining to typical site installations and applications. Contact
Thomson Technology for further information as may be required.

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5. GENERAL THEORY OF OPERATION
5.1. AUTOMATIC SEQUENCE OF OPERATION
Note: Time delays indicated below are factory default settings only. Refer to Section 18.15 of this
manual for alternate time delay settings available on TSC 9 Controller
UTILITY POWER FAIL When voltage drops on any phase of the utility supply below 70%
of rated voltage, a generator start sequence will be initiated.
GEN START The generator will start following expiry of the 3 second Gen
Start timer.
GEN WARM-UP A generator warm-up period will be initiated once the generator
starts and reaches 80% rated voltage and 90% rated frequency.
TRANSFER TO GEN The load will transfer to the generator supply following expiry of
the 10 second Gen Warm-up timer.
LOAD SHED ACTIVATE All non-essential loads connected to Load Shed control circuit
will be de-energized once generator transfers on load (If kW
Load Shed option is installed, refer to Section 18.16 of this
manual for further details).
UTILITY POWER RETURN When utility power is restored to above 80% rated voltage on all
phases, a utility power return sequence will be initiated.
TRANSFER TO UTILITY The load will transfer from generator to utility power following
expiry of the 120 second Utility Return timer, provided both
generator and utility voltages are in-phase at time of transfer.
LOAD SHED RESET All non-essential loads connected to Load Shed control circuit
will be re-energized once load transfers to utility power.
GEN COOL DOWN The generator will automatically stop following expiry of the 2
minute Gen Cool Down timer.
5.2. SERVICE ENTRANCE AUTOMATIC TRANSFER SWITCH OPERATION
5.2.1. OVER CURRENT TRIP
Should the utility breaker trip open due to an over current condition, TSC 9 transfer
controller will initiate an engine start signal and will permit transfer of the load to the
generator supply. The utility source will be locked out and the load will remain on the
generator supply until the Utility Service Entrance breaker is manually reset.
5.2.2. SERVICE DISCONNECT PROCEDURE
To initiate a Utility Supply Service Disconnect, follow procedure shown below:
5.2.2.1. TURN OFF GEN STARTING CONTROL: At the generator set,
turn it’s automatic starting control to OFF position to prevent generator

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set from automatically starting when the Utility Service disconnect
breaker is opened.
5.2.2.2. LOCK OPEN GENERATOR CIRCUIT BREAKER: At the
generator set, OPEN its main generator output power circuit breaker.
Attach safety lockout padlock to the circuit breaker to prevent
unauthorized change in operating condition.
WARNING!
Failure to lock open the main generator output
circuit breaker may result in serious personal
injury or death due to electrical shock.
5.2.2.3. LOCK OPEN UTILTY SERVICE DISCONNECT BREAKER: At
the transfer switch, OPEN the Utility Service disconnect circuit
breaker. Attach safety lockout padlock directly onto the Service
Disconnect Utility circuit breaker toggle hasp provided to prevent
unauthorized change in operating condition.
NOTE!
On NEMA 3R rated Transfer Switches, A door
locking Padlock hasp is also provided in cases
where the padlock does not fit behind the
NEMA 3R door when closed.
WARNING!
Failure to lock open the Utility Service
disconnect circuit breaker may result in serious
personal injury or death due to electrical shock.
DANGER!!!!
Arc Flash and Shock Hazard. Will cause severe injury or death.
Do not open equipment until ALL power sources are disconnected

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This equipment must be installed and serviced only by qualified electrical
personnel utilizing safe work practices and appropriate Personal Protective
Equipment (PPE). Failure to do so may cause personal injury or death
5.2.3. RETURN FROM SERVICE DISCONNECT MODE
To return the system back to automatic operation following a Service Disconnect
mode, follow procedure shown below:
5.2.3.1. CLOSE ATS ENCLOSURE DOOR: Prior to Load re-
energization, ensure the transfer switch enclosure door/front cover is
adequately closed with all provided fasteners.
5.2.3.2. CLOSE UITLITY SERVICE DISCONNECT BREAKER: To re-
energize the load, remove the padlock(s) from the Utility Service
Disconnect Circuit Breaker and or ATS door, and move the circuit
breaker to the CLOSED position. The Load will be re-energized and
the transfer switch will remain in the utility supply position.
5.2.3.3. CLOSE GENERATOR CIRCUIT BREAKER: At the generator
set, re-close the main generator output power circuit breaker.
5.2.3.4. RE-ENABLE AUTOMATIC GEN STARTING CONTROL: At the
generator set, turn its automatic starting control back to the
AUTOMATIC position to return the system back to fully automatic
operation.

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6. OVER CURRENT PROTECTION
6.1. STANDARD TS 910 AUTOMATIC TRANSFER SWITCH
The standard TS 910 Automatic Transfer Switch does not contain any integral over current
protection and requires upstream over current protection devices for both Utility and
Generator sources. The Standard TS 910 is rated for 100% continuous loading and can
withstand a maximum short circuit fault current as noted in Section 17 of this manual. The
standard TS 910 transfer switch model without integral over current protection is identified in
the product model code. Refer to Section 4.1 of this manual for further details on model
coding.
6.2. SERVICE ENTRANCE RATED TS 910 AUTOMATIC TRANSFER SWITCH
TS 910 transfer switches have integral over current protection supplied on the Utility source
as standard. For transfer switches rated 100A through 400A, over current protection is non-
adjustable thermal-magnetic type.
7. GENERAL NOTES ON SERVICING TRANSFER SWITCH
MECHANISM
DANGER!!!!
Arc Flash and Shock Hazard. Will cause severe injury or death.
Do not open equipment until ALL power sources are disconnected
This equipment must be installed and serviced only by qualified electrical
personnel utilizing safe work practices and appropriate Personal Protective
Equipment (PPE). Failure to do so may cause personal injury or death
Only qualified personnel should undertake Service work. Failure to correctly maintain an
automatic transfer switch may present a hazard to life and equipment. Full operational
testing must be done prior to placing a transfer switch in service subsequent to any
maintenance or repair. Any service work involving electrical components requires high-
potential testing to ensure that required insulation levels have been maintained.
When performing any service work on the transfer mechanism, it is imperative that the
following be observed:

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To maintain mechanical integrity, ensure that:
•All fasteners are adequately tightened.
•The operating shaft is not damaged or bent, and that all bearing points operate
freely.
To maintain electrical integrity, ensure that:
•All electrical connections, especially power connections, are clean and
adequately tightened. Corroded or loose power connections will cause
destructive heating, and may cause premature tripping.
•All insulating devices are in place and in good condition.
•No moisture or other contamination is present.
•Electrical conductors are adequately secured away from moving parts.
To maintain operational integrity, ensure that:
•All control devices are in good condition and correctly calibrated.
•All control devices are adequately secured in their plug-in fixtures.
8. TRANSFER SWITCH MECHANISM OPERATION
The transfer mechanism is a power contactor assembly. The transfer switch mechanism has only
two possible positions: Utility contacts closed or Generator contacts closed. There is no neutral
position.
8.1. AUTOMATIC OPERATION
During automatic operation, the TSC 9 controller issues pulsed control signals to each of the
power contactor solenoids for the utility and generator supply. Two solenoids are utilized,
one for utility supply, one for the generator supply. The two solenoids are electrically
interlocked and are intermittent duty rated only (i.e. they cannot be continuously energized
otherwise damage will result).
8.2. MANUAL OPERATION
The transfer switch maybe operated manually for maintenance or emergency operation
conditions provided both Utility and Generator supplies are de-energized prior to manual
operation.
DANGER
DANGERDANGER
DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION, OR ARC FLASH
•This equipment must be serviced only by qualified electrical personnel utilizing safe
work practices and appropriate Personal Protective Equipment (PPE).

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•Many components of this equipment operate at line voltage. DO NOT TOUCH. Use
only electrically isolated tools.
•Install and close all covers before applying power to this equipment
•Do not open covers to equipment until ALL power sources are disconnected
Failure to do so may cause personal injury or death
Once both Utility and Generator supplies are de-energized the following procedure can be
used to operate the Transfer Switch manually.
a) Up-plug the TSC 9 controller isolation plug (J4) to prevent automatic operation.
b) Open ATS enclosure and locate Manual Operation Handle provided with the transfer
switch (see photos below)
100A/200A ATS Handle 400A ATS Handle
c) Insert manual handles onto the transfer switch mechanism at locations shown in the
following diagrams.
100A/200A Contactor Mechanism 400A Contactor Mechanism
d) To manually operate mechanism to the utility supply position, rotate handle
upwards. Do not over-torque handle once position has been attained.
Insert Manual Handle
on mechanism here
Insert Manual Handle
on mechanism here

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e) To manually operate mechanism to the generator supply position, rotate
handle downwards. Do not over-torque handle once position has been
attained.
f) Once ATS is manually operated to desired position, re-install enclosure cover,
then re-energize supply sources to re-energize the load.