THOMSON TS 850 Service manual

TS 850
AUTOMATIC TRANSFER SWITCHES
INSTALLATION, OPERATING &
SERVICE MANUAL
PM042
Rev 7 01/10/17
9087A
-198
1
h
Street, Langley,
BC
Canada V1M 381 • Telephone [phone]
Telefax [phone] • E-Mail: [e-mail] • www.thomsontechnology.com

TS
850 TRANSFER SWITCH
TABLE OF CONTENTS
1.
PRODUCT REVISION HISTORY 1
2.
CAUTION! 1
3.
NOTESTOINSTALLER
1
4.
GENERAL DESCRIPTION 3
5.
GENERAL THEORY
OF
OPERATION 4
6.
TYPE A AND TYPE B DEFINITIONS 8
7.
GENERAL NOTES
ON
SERVICING MECHANISM 8
8.
STYLE
"T"
TRANSFER SWITCH MECHANISM- 400 -1200 AMP 9
9.
STYLE
"M"
TRANSFER SWITCH MECHANISM -MAXIMUM 250 AMP 10
10. RECOMMENDED MAINTENANCE (STYLE
"T"
& STYLE
"M"
MECHANISMS)
11
11. FRONT VIEW (TYPICAL) 3
I
4 POLE STYLE
"T"
TRANSFER MECHANISM 13
12. STYLE
"T"
CONFIGURATION OPTIONS 14
13. FRONT VIEW (TYPICAL)
3/4
POLE STYLE
"M"-
100/150/250A 15
14. FRONT VIEW (TYPICAL) 3 POLE STYLE
"M"-
200A 16
15. TROUBLESHOOTING (SEE CAUTION!
ON
PAGE #1) 17
16. CABLE TERMINAL INFORMATION 18
17. REQUIREMENTS FOR UPSTREAM CIRCUIT PROTECTIVE DEVICES 19
18. GROUND FAULT SITE TEST REQUIREMENTS
20
19. NOTES
20
20. PERFORMANCE TESTS
21
PM042 Rev
7
01/10/17
Thomson Technology Inc.

TS
850 TRANSFER SWITCH
1.
PRODUCT REVISION HISTORY
NOTE:
The
following
information
provides an historical
summary
of
changes
made
to
this
product
since
the
original release.
Operating
&
Seniice
Manual Version
Rev 7 01/10/17 Withstand rating change for 1
OOA
&
150A.
Rev 6 01/07/20
NewTS
850-TS7-1000/1200
model introduced; ground fault test
requirements; performance tests.
Rev 5 00/12/01 New
TS
850-TCK-600 model introduced; cable terminal
information; DSS option Lev-3 information available
in
PM043.
Rev 4 00/08/31 Service entrance information for all models.
Rev 3 00/02/25 Warnings added with reference to multi-tap controller capability
features and system voltage; added manual operation instructions.
Rev 2 00/01/21 Added 200A model information c/w drawings.
Rev 1 98/01/21 Separated TSC800 controller information into new manual PM049.
Rev 0 96/08/28 Original release.
Contact
Thomson
Technology
Inc., 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.
All information contained
in
this manual is
for
reference
only
and is
subject to
change
without
notice.
2.
CAUTION!
Before opening the transfer switch enclosure to perform any service task, or to manually transfer the
mechanism, it
is
imperative to isolate the transfer switch from any possible source of power. Failure
to do so may result
in
serious personal injury or death due to electrical shock.
Service procedures must
be
undertaken by qualified personnel only!
3.
NOTES
TO
INSTALLER
To ensure satisfactory installation
of
this equipment
be
sure to observe "Recommended Connection
Tightness" and "Requirements for Upstream Circuit Protective Devices" located
in
this manual.
PM042
Rev
7
01110117
1
Thomson
Technology
Inc.

TS
850 TRANSFER SWITCH
All mechanical and electrical connections must
be
checked for tightness prior to placing this
equipment
in
service to ensure proper operation and to validate applicable warranty coverage.
If the transfer switch has programmable multi-tap voltage capability (refer to electrical schematic),
confirm the transfer switch has been·configured for the system voltage prior to installation.
.·Warning
Failure ·to confirm and match transfer switch
voltage
with
,<
the system voltage . could cause
serious equip,;,eni
da
in
age; .
The voltage selections and connections are shown
on
the electrical schematics attached to each
transfer switch. The factory default settings will
be
indicated
on
the calibration label attached on the
inside of the enclosure door (supplied loose
on
open style models). A blank label
is
included to
record the applicable settings if the configuration is changed from the factory default settings.
To change the transfer switch configuration the following must
be
accomplished:
• Change voltage taps
of
PT's to system voltage (refer to schematics)
• Change TSC 800 programming (refer to sections 6.2.
2,
6.2.4, 6.2.5,6.3, and 6.4
of
the TSC
800 instruction manual). The following settings may require reprogramming (depending
on
options purchased):
~
System voltage
~
System frequency
~
System phase
~
Utility undervoltage pickup (typically 90% of system voltage)
~
Utility undervoltage dropout (typically 80%
of
system voltage)
~
Utility overvoltage pickup (typically 110% of system voltage)
~
Utility overvoltage dropout (typically 105%
of
system voltage)
~
Utility underfrequency (typically 95% of system frequency)
~
Utility overfrequency (typically 105% of system frequency)
~
Generator undervoltage pickup (typically 90% of system voltage)
~
Generator undervoltage dropout (typically 80% of system voltage)
~
Generator overvoltage pickup (typically110% of system voltage)
~
Generator overvoltage dropout (typically 105% of system voltage)
PM042 Rev·7
01/10117
2
Thomson
Technology
Inc.

TS
850 TRANSFER SWITCH
~
Generator underfrequency (typically
95%
of system frequency)
~
Generator overfrequency (typically 105% of system frequency)
Record any changed setting
on
the TSC
800
Programming Data Sheets for future reference.
Complete the blank calibration label
and
attach to the inside ofthe transfer switch enclosure door.
INSTALLATION
OF
OPEN TYPE TRANSFER SWITCHES -
Please refer to the factory for
additional information.
4.
GENERAL DESCRIPTION
(See CAUTION! on Page #1)
The automatic transfer switch employs two moulded-case switching devices which may
be:
a)
non-automatic circuit interrupters ("type
A"
transfer switch)
b)
automatic circuit interrupters with integral trip units; ("type
B"
transfer switch)
In
this manual, the switching devices will
be
referred to
as
"breakers". The breakers are operated
by a mechanism driven with
an
electric motor. The transfer switch provides automatic transfer of
an
electrical load to a standby power supply
in
the event of drop or loss of voltage of any or
all
phases
of the primary power supply. Upon restoration of the primary supply, the electrical load
is
automatically retransfered to the primary power supply (after
an
adjustable time delay). All
necessary control components for automatic transferring are located
in
the control compartment
and
on
the enclosure door.
The transfer motor utilizes the power from the source to which the electrical load
is
being
transferred. The mechanism provides a positive mechanical interlock to prevent both breakers from
being closed at the same time. The mechanism
is
also designed to leave both breakers "trip free"
in
the closed position, permitting incorporation of overload and/or short-circuit protection
in
either or
both breakers ("type 8"). After tripping, the breaker of a "type
B"
transfer switch must
be
manually
reset.
Note: For the purpose of this manual, the term UTILITY indicates the primary power,
and
the term
GENERATOR indicates the standby power.
PM042
Revt
01110/17
3
Thomson
Technology
Inc
.

TS
850 TRANSFER SWITCH
5.
GENERAL THEORY OF OPERATION
5.1. STANDARD AUTOMATIC TRANSFER SWITCH
5.1.1.
NORMAL OPERATION
When utility supply voltage drops below a preset nominal value (adjustable from
70%
to 1
00%
of nominal)
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 (adjustable from 0 to
60
sec.)
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. Once the generator voltage
and
frequency rises above
preset values (adjustable from
70%
to
100%
of nominal), the engine warmup timer
will
be
initiated. Once the warmup timer expires (adjustable from 0 to
60
sec.
),
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
the motor driven mechanism. Note:
An
optional neutral delay timer circuit
will delay the transfer sequence
in
the neutral position (i.e. both breakers open) until
the selected time expires (adjustable from 0 to
60
sec.).
The generator will continue to supply the load until the utility supply has returned.
The retransfer sequence
is
completed
as
follows: when the utility supply voltage
is
restored to above the preset values (adjustable from
70%
to 100% of nominal)
on
all
phases, a transfer return delay circuit
will
be
initiated. Following expiry of the
Transfer Return Timer (adjustable from 0 to
30
min.), 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 retransfer the load from the generator supply back to the utility supply. Note:
An
optional neutral delay timer circuit will delay the transfer sequence
in
the neutral
position (i.e. both breakers open) until the selected time expires (adjustable from 0 to
60
sec.).
An
engine cooldown timer circuit will
be
initiated once the load
is
transferred from the
generator supply. Following expiry of the cooldown delay period (adjustable from 0
to
30
min.), the engine start signal will
be
removed (contact opening) to initiate
stopping of the generator set.
·
PM042
Rev!
·
01110!17
4
Thomson
Technology
Inc
. ·

TS 850 TRANSFER SWITCH .
5.2. SERVICE ENTRANCE AUTOMATIC TRANSFER SWITCH
(Note: This applies only to service entrance transfer switches supplied with a
Padlockable Disconnect Switch. Contact TTl for other types.)
5.2.1. NORMAL OPERATION
·Underc norma1 conditions, the load is :- energiz~d from the utility supply through the
closed utility transfer breaker. If the utility power fails, the generator will start and the
load will
be re-energized via the closed generator transfer breaker.
In the normal operating mode, the Service Disconnect switch shall be in the
"energized" position.
5.2.2. SERVICE DISCONNECT PROCEDURE
To perform a service disconnect (i.e. to disconnect the utility and generator supplies),
the following procedure
is required:
1. Move the "Service Disconnect" control switch located on the door of the transfer
switch to the "Disconnected" position.
2. Verify that the "Service Disconnected" pilot light is illuminated. If the Light is
illuminated, the service has been successfully disconnected
and it is safe to perform
any maintenance procedures as required. In this condition, the transfer switch is in
the neutral position, with both utility and transfer breakers open. The transfer switch
will remain
in this condition, regardless of condition of the utility and generator
supplies (i.e. if the utility power fails, the generator will not receive a start condition,
nor will the transfer switch move to the generator position).
If the Light is not
illuminated, further procedures are required (refer to the following procedure #4).
3. Attach safety lockout padlock to the "Service Disconnect" control switch to prevent
unauthorized change
in operating condition and verify transfer switch door is locked
closed. Ifthe door
is not locked, turn and remove door key.
4. If the "Service Disconnected" pilot light is not illuminated, the service will not have
been successfully disconnected and
it is therefore not safe to perform any
maintenance until the following additional procedures are performed:
Warning ,
· rj£irspnp~l ~:;, ,-nus( ,::,· un~~ii~k.~ ·-
PM042 Rev 7 01/1. 0/17
,_. _____ ,·.
· TfJomson Technology Inc. ·

TS
850
TRANSFER
SWITCH
• Open the door to the transfer switch using a suitable tool
and
opening the door
lock with the key.
• Visually inspect the actual position of the transfer switch mechanism.
If
the
position
of
the transfer switch mechanism is clearlv in the "neutral position", the
service has been successfully disconnected.
Notes:
1)
If the position of the transfer switch mechanism
is
clearly
in
the "neutral
position, the "service disconnected" pilot light may not have illuminated
due to the following reasons:
a)
Utility
and
generator supply voltages are not present (the pilot light
requires
AC
supply voltage to
be
present).
b)
The pilot light may
be
burnt out. The bulb should
be
immediately
replaced with a suitably rated bulb.
c)
Failure of one or more of the sensing/logic contacts. A qualified
service technician
is
required to trouble shoot this specific condition.
Unplug the control circuit isolation plug to de-energize all
AC
power to
the control circuits. Note: The
AC
power conductors will still remain
energized. Once the control circuit isolation plug
is
removed the
"Service Disconnected" pilot light will not illuminate due to loss of
control power.
Note:
to return the transfer switch back to normal operation, the
control circuit isolation plug must
be
reconnected for correct
operation.
• The transfer switch door should then
be
securely closed using a suitable tool and
locked
in
the closed position
with
the
key.
Once the transfer switch door has
been positively locked closed
and
secured and only then
is,
it
is
safe to perform
any maintenance procedures
as
required.
•
If
the position
of
the transfer switch mechanism is
not
in the "neutral position"
further procedures are required (refer to the following procedure)
PM042 Rev
7
01/10/17
·
Warni11g
Failure to ·positively lock -closed .
and
secure .
the
transfef
switch
door
may
· result in serious
per
sonal
'i
njury
or
death due to electrical_
shock.
. 6
Thomson
Technology
Inc
.

,; TS 850 TRANSFER SWITCH
• If the position of the transfer switch mechanism is not in the "neutral position" the
transfer switch mechanism must
be manually operated as follows. To operate
manually, pull the manual release plunger
on the mechanism, releasing the motor
drive
rod from motor drive arm and move the knob and yoke to the marked
"Neutral" position.
_Warning ··
Failure to move
. -':-:
The transfer switch door should then be securely closed using a suitable tool and
locked
in the closed position with the key. Once the Transfer switch door has been
positively locked closed
and secured and only then is, it is safe to perform any
maintenance procedures
as required.
Warning .
Failure.to positively lock clqsed ana ~ secure the ·
. ;: .·,·- . __ ·.-· .
transfer. switqh door miw result . in serious
personal injurv
or death due to .electrical shock.
To re-energize the load, the padlock(s) should be removed from the "Service
Disconnect" control switch,
and move the switch to the "Energized" position. The
transfer switch will immediately return
to the utility or generator supply if within normal
operating limits.
5.3. TEST CONDITION
The transfer switch may be tested utilizing the TSC 800 controller push-buttons or
optional four position test switch. A simulated utility power failure condition will
be
activated when the test mode is selected. The transfer switch will operate as per a
normal utility power fail condition. Note the test mode
is operator selectable for "On-
Load" or "Off-Load" testing scenarios.
The transfer switch will remain
on generator supply until the test mode is terminated.
It will then immediately transfer back to the utility supply and then continue to operate
the generator set for
its cooldown period then stop. Note: the transfer switch will
automatically return to the utility supply (if within nominal limits) if the generator set
fails while
in the test mode.
. PM042 · Rev7 01/10117 1'
,·
, Thomson Technology Inc.

TS 850 TRANSFER SWITCH
6. TYPE A AND TYPE B DEFINITIONS
"Type A" transfer switch means an automatic transfer switch that does not employ integral
overcurrent devices.
"Type
B" transfer switch means: -an .. automatic·transfer switch that does employ integral overcurrent
protection
in at least one of its two breakers.
"Type
A" transfer switches are not equipped with trip units, and require properly coordinated
upstream protection. Information
on closing and withstand ratings, and recommendations for
maximum upstream protective devices for "type
A" units are in this manual. (Note: Some "Type A"
models employ "high-magnetic" trips in the breakers, however these are set to trip at a higher than
normal current for that amperage circuit, therefore the possibility of tripping is very remote. Since
these trips are not intended to provide overcurrent protection, but are rather employed
to ensure the
integrity of the transfer switch under
all circumstances, they are still classed as "Type A").
"Type
B" transfer switches are typically equipped with standard thermal-magnetic trips which will
provide the required overload and short circuit protection. "Type
B" can also be built using solid
state trip breakers, which
can include ground fault tripping as well as overload and short circuit
protection.
It should be noted that a "Type B" transfer switch with overcurrent protection in only one breaker will
require the same consideration for upstream protection
in the feeder of the breaker with no trip (as
applies to a "Type A" transfer switch).
7. GENERAL NOTES ON SERVICING MECHANISM
(See CAUTION! on Page #1)
When performing any service work on the transfer mechanism, it is imperative that the following be
observed:
7.1. To maintain mechanical integrity, ensure that:
• All limit switches linkages are correctly adjusted to provide full travel of the
breaker toggles
without exerting unnecessary forces associated with excessive
travel. Ensure that breakers travel far enough to reset any internal trip unit (it
is
more important for the toggle to go fully in the "off' direction, than in the "on"
direction).
• Mechanical interlocking
is correct one breaker must be well open before the other
should close.
. PM042 Rev 7 01110117
'- .. .T hp mson Technology Inc. ·