ASEA AC125V-3 User manual

Operations Manual
for the ASEA Power Systems
Model AC125V-3
3 Phase Yacht Power Converter
P/N 605053 B
Issued 4/27/2007

AC125V-3 Operations Manual....2
CERTIFICATION
ASEA Power Systems certifies that this product was thoroughly tested and inspected and found to meet or
exceed its published specifications when shipped from the factory.
WARRANTY
ASEA Power Systems warrants each unit to be free from defects in material and workmanship. For a period
of 18 months after purchase or 12 months after installation (whichever is shorter), ASEA Power Systems will
repair or replace any defective module provided the unit has been installed and operated in a manner
according to this manual. A thorough inventory of spare parts & modules is maintained at our factory. Our
world wide sales/support facilities also inventory a complement of spare parts and modules.
ASEA Power Systems is not responsible for consequential damage arising from the use of its equipment.
It does not apply to extensively modified or non-standard systems. Debit memos for returned units are not
accepted, and will cause return of the system without repair.
LIFE SUPPORT POLICY
ASEA Power Systems does not authorize the use of any of its products or systems for use an AC voltage
supply (source) for life support systems. Life support systems are devices which support or sustain life, and
whose failure to perform, when properly used in accordance with this Operations Manual, can be reasonably
expected to result in significant injury to the user.

AC125V-3 Operations Manual....3
1 USING THIS MANUAL
This manual has been written as an Operations Manual. Installation, Operations, and Preventative
Maintenance are covered in detail. This manual will cover the following model:
AC125V-3 125kVA 3 Phase Yacht Power Converter
Please note that this converter is capable of being paralleled for higher power applications.
The Model AC125V-3 can be paralleled to produce the following models:
AC250V-3/2 250kVA 3 Phase Yacht Power Converter
AC375V-3/3 375kVA 3 Phase Yacht Power Converter
AC500V-3/4 500kVA 3 Phase Yacht Power Converter
It is important that the operator reads this manual prior to installing and operating the converter. A
thorough understanding of the information covered in this manual is required for proper installation
and operation.
If any questions arise while reading this manual, the user is encouraged to call ASEA Power
Systems. ASEA Power Systems is located at:
ASEA Power Systems
15602 Commerce Lane
Huntington Beach, CA. 92649
Phone [phone]
FAX [phone]
Web http://www.aseapower.com

AC125V-3 Operations Manual....4
TABLE OF CONTENTS
CERTIFICATION .............................................................2
WARRANTY ................................................................2
1 USINGTHISMANUAL ..................................................3
2 SAFETYNOTICES......................................................6
3 INTRODUCTIONTOTHEAC125V-3 ......................................8
4 SPECIFICATIONS .....................................................10
4.1 ELECTRICALSPECIFICATIONS...................................10
4.1.1 InputService ..............................................10
4.1.2 OutputService .............................................10
4.1.3 Control,Metering,andStatus .................................12
4.2 PHYSICALSPECIFICATIONS .....................................12
4.2.1 Mechanical .............................................12
4.2.2 Environmental .............................................12
5 INSTALLATION.......................................................13
5.1 MECHANICALINSTALLATION ...................................14
5.2 ELECTRICALINSTALLATION ....................................17
5.2.1 InputPowerConnections .....................................18
5.2.2 OutputPowerConnections ...................................18
5.2.3 SeamlessTransferConnections ................................21
5.2.4 Multi-Cabinet..............................................23
6 OPERATION ..........................................................24
6.1 POWERTURN-ONPROCEDURE ..................................24
6.1.1 Systems Without Seamless Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.2 Systems With Seamless Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 MULTI-CABINET TURN-ON PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 AUTO-RESTARTFEATURE ......................................31
6.4 TURN-OFFPROCEDURE .........................................33
6.4.1 Systems Without Seamless Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4.2 Systems With Seamless Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.5 REMOTECOMMUNICATION .....................................35

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7 SOFTWAREFEATURES................................................40
7.1 GENERAL......................................................40
7.2 LOADMANAGEMENT...........................................40
7.3 LOADMANAGEMENTOPERATION ...............................42
7.3.1 Shore Cord Alarm, Single, Master, and Slave converters . . . . . . . . . . . . 42
7.3.2 Shore Cord Setup, Single, Master, or Slave Converters . . . . . . . . . . . . . 43
7.3.3 Load Sharing, Slave converters with Shore Cord Management Option . 44
7.3.4 Voltage Droop, Single or Master Converters . . . . . . . . . . . . . . . . . . . . . . 46
7.3.5 Automatic Transfer to Generator, Single or Master Converters (Seamless
Transferinstalled) ..........................................47
7.3.6 Quick Setup of Shore Cord Alarm, Single, Master, or Slave Converters 48
7.3.7 Expert Load Sharing Use, Paralleled Converters . . . . . . . . . . . . . . . . . . . 49
7.4 GENERATOR FREQUENCY ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.5 CONVERTER OUTPUT IMPEDANCE CONTROL . . . . . . . . . . . . . . . . . . . . . 50
7.6 AGCCONTROL .................................................51
7.7 kW-HOUR METER AND MAXIMUM POWER LEVEL DISPLAY . . . . . . . . 52
7.8 CONVERTER OUTPUT VOLTAGE CONTROL . . . . . . . . . . . . . . . . . . . . . . . 53
7.9 EVENTLOG ....................................................54
8 DIAGNOSTICS ........................................................56
9 CALIBRATION........................................................59
10 MAINTENANCE ......................................................61
11 INTERNATIONAL POWER FORM REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
FIGURES
1 SYSTEMBLOCKDIAGRAM .............................................8
2 MECHANICALOUTLINE...............................................15
3 CONTROLS ..........................................................16
4 INPUTANDOUTPUTCONNECTIONS ...................................18
5 SEAMLESS TRANSFER PCB CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 FRONTPANELCONTROLS.............................................24
7 RS-232CPINOUT ......................................................36
8 STATUSWORDBITDEFINITIONS ......................................58

AC125V-3 Operations Manual....6
2 SAFETY NOTICES
Each shore power converter is capable of transferring large amounts of electrical energy very
quickly. This quality is fundamental to a high performance power converter. International symbols
are used throughout this manual to stress important information. Read the text below each symbol
carefully and use professional skills and prudent care when performing the actions described by the
text.
THE CAUTION SYMBOL (TRIANGLE ENCLOSING AN EXCLAMATION POINT)
INDICATES A CONDITION THAT COULD SERIOUSLY DAMAGE EQUIPMENT AND
POSSIBLY INJURE PERSONNEL. CAUTIONS WILL BE PRESENTED IN THIS FORM.
ALL CAUTIONS SHOULD BE RIGOROUSLY OBSERVED.
THE WARNING SYMBOL (TRIANGLE WITH A LIGHTNING BOLT) IS USED TO
SIGNAL THE PRESENCE OF A POSSIBLE SERIOUS, LIFE THREATENING
CONDITION. A CONDITION THAT IS HAZARDOUS TO BOTH PERSONNEL AND
EQUIPMENT WILL BE ISSUED AS A WARNING. ALL WARNINGS WILL BE
PRESENTED IN THIS FORM.

AC125V-3 Operations Manual....7
CTHIS EQUIPMENT CONTAINS HIGH ENERGY, LOW IMPEDANCE CIRCUITS!
LETHAL POTENTIALS ARE CONTAINED WITHIN THE SYSTEM EVEN WHEN
IT IS APPARENTLY NOT OPERATING.
CCARE MUST BE EXERCISED WHEN SERVICING THIS EQUIPMENT IN ORDER
TO PREVENT SERIOUS OPERATOR INJURY OR EQUIPMENT DAMAGE.
CDO NOT WORK ON OR OPERATE THIS EQUIPMENT UNLESS YOU ARE
FULLY QUALIFIED TO DO SO. NEVER WORK ALONE.
CTHE EQUIPMENT IS NOT IGNITION RATED, IT MUST NOT BE OPERATED IN
AREAS WHERE COMBUSTIBLE GASES MAY ACCUMULATE.
COBSERVE THE FOLLOWING WHEN SERVICE AND MAINTENANCE ARE
REQUIRED:
CREMOVE ALL JEWELRY FROM ARMS AND NECK WHEN SERVICING THIS
EQUIPMENT. THIS PREVENTS THE POSSIBILITY OF SHORTING THROUGH
THE JEWELRY, OR ELECTROCUTION OF THE OPERATOR.
CWEAR SAFETY GLASSES WHEN SERVICING THIS EQUIPMENT TO PREVENT
EYE INJURY DUE TO FLYING PARTICLES CAUSED BY ACCIDENTAL SHORT
CIRCUIT CONDITIONS.
CDO NOT REMOVE ANY PANELS OR COVERS WITHOUT FIRST OPENING ALL
SHORE POWER AND SWITCHGEAR CIRCUIT BREAKERS DISTRIBUTING
POWER TO AND FROM THE CONVERTER, AND THEN REMOVING THE
INPUT SERVICE.
CSERVICE SHOULD BE REFERRED TO PERSONNEL AUTHORIZED BY THE
FACTORY TO SERVICE THIS EQUIPMENT.

AC125V-3 Operations Manual....8
3 INTRODUCTION TO THE AC125V-3
The AC125V-3 is a high performance Yacht Power Converter utilizing dual-conversion technology.
The system will accept any three phase input service with a frequency between 40-70Hertz, and a
voltage between 330-520VAC.
The output power form has been programmed at the factory for the voltage and frequency required
by your yacht.
Dual-conversion technology is the preferred technique for AC power conversion, and was chosen
for the system. In this technology, the shore power service is isolated by the transformer, then
converted to DC power by the phase multiplier power supplies. The output inverters then convert
the DC power back to the required AC form (both voltage and frequency) required by the yacht.
Being a converter designed from the ground up specifically for the yachting industry, all efforts have
been made to produce a system capable of withstanding the marine environment. All system
FIGURE 1 SYSTEM BLOCK DIAGRAM

AC125V-3 Operations Manual....9
components are packaged in one drip-proof, dust-resistant stainless steel enclosure. Major
components are internally modular, allowing a simple exchange in the unlikely event of failure.
Complete maintenance and service can be provided with only top and front access to the system.
Three lightweight power modules can be removed and replaced through the front panel for repair
or power level upgrade.
System operation is managed through three basic operators. A safety disconnect on the front of the
enclosure is used for securing input service during maintenance and service. Three membrane switch
groups in the control console, SHORE POWER, CONVERTER POWER, and SHIP’S POWER,
provide normal operation of the system. Each switch group contains an ON and OFF switch with
associated LED indicators.
In addition to the basic function of power conversion, the converter provides the user with a
sophisticated power analysis and monitoring capacity. All parameters for input and output power,
along with operations and status information, are available on the front panel display console.
Various displays are selected through a long life, sealed membrane switch panel.
For additional information on controls and indicators, please refer to Section 6.

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4 SPECIFICATIONS
4.1 ELECTRICAL SPECIFICATIONS
Parameter AC125V-3
4.1.1 Input Service
Input Power Form Three Phase
AC
Input Voltage Range 330-520V
Input Frequency Range 40-70 Hertz
RMS
Input Current, Max. Three Phase 189 A
RMS
Input Current, Soft Start, Max. 30 A
Input Current Distortion <8% THD @ rated load
Input Power Factor >0.98 @ rated load
4.1.2 Output Service
Output Power Rating 125kVA @ 0.8 p.f.
AC AC AC AC
Output Power Form Three-Phase 220/380 V , 230/400 V , 240/416 V , 254/440 V ,
AC
and 277/480V (auto-transformers required for 480VAC output)
Output Frequency 50 or 60 Hertz
Output Frequency Accuracy 0.01%
Output Voltage Distortion < 1% THD
Output Voltage Line Regulation 0.50%
Output Voltage Load Regulation 1.0%
Output Voltage Response Time 0.20 msec.
Output Current, Continuous Refer to Table 1 on the following page for basic ratings.
Output Current, Peak 225% of cont. rating
Output Current, Surge 150% of cont. rating
Conversion Efficiency 94% @ rated load

AC125V-3 Operations Manual....11
4 SPECIFICATIONS
4.1 ELECTRICAL SPECIFICATIONS,cont.
4.1.2 Output Service, cont.
Table 1 - Output Current, Rated Continuous RMS
Output Form AC125V-3
RMS RMS
3Ø, 277/480V * 150A /Ø
RMS RMS
3Ø, 254/440V 164A /Ø
RMS RMS
3Ø, 240/416V 174A /Ø
RMS RMS
3Ø, 230/400V 181A /Ø
RMS RMS
3Ø, 220/380V 189A /Ø
* The 480V power form requires the use of 3 ea. auto-transformers.
Auto-transformer specifications
Dimensions: TBD Height, TBD Width, TBD Depth (w/o secondary bus terminals and TBD Depth
w/ secondary bus terminals)
Weight: TBD lbs. each
Heat dissipation under full load: 30 degrees C over ambient at full load measured at a hot spot near
the center steel leg.
Part Number: TBD

AC125V-3 Operations Manual....12
4 SPECIFICATIONS, cont.
4.1 ELECTRICAL SPECIFICATIONS, cont.
4.1.3 Control, Metering, and Status
Input Power Control Input Service Disconnect Switch, 2 pos.
Shore Power Control Membrane Switch, Input ON/OFF Control
Ship’s Power Control Membrane Switch, Output ON/OFF Control,
Converter Power Control Generator/Shore Power Transfer Control
Shore Power Metering Voltage, Current, Frequency, kVA, kW, %Load
Converter Power Metering Voltage, Current, Frequency, kVA, kW, %Load
Generator Power Metering Generator 1 & 2 Voltage, Frequency
(Optional) Current, kVA, kW, %Load
System Status Operational status, Diagnostics, Software Calibration
4.2 PHYSICAL SPECIFICATIONS
Parameter AC125V-3
4.2.1 Mechanical
Height 65.13"/165cm
Width, Enclosure 25"/63.5cm
Depth 23"/58.4cm
Weight 1825lbs/828kg
4.2.2 Environmental
Ambient Temperature Range 0-50°C non-condensing
Air Exchange Rate 900CFM

AC125V-3 Operations Manual....13
5 INSTALLATION
The installation section is divided into two parts. The first will cover mechanical installation, the
second, electrical installation.
Read this manual thoroughly prior to attempting the installation. Improper installation is the most
significant cause of system start-up problems and service issues over the product’s life. Upon receipt
of the equipment, perform an external visual inspection. Verify that nameplate information is
consistent with the ship’s power requirements (required form, voltage, and frequency).
Proper planning will speed up installation, location, and connection of the equipment. Follow the
suggested minimum clearances provided in Table 2. Ensure the room/compartment has adequate
ventilation and cooling. The thermal load presented by the converter will be substantial,
approximately 20,313BTU/Hr at maximum continuous load for the AC125V-3.
THE CONVERTERS ARE HEAVY, WEIGHING 1825lbs. EXTREME
CAUTION MUST BE EXERCISED IN HANDLING AND INSTALLATION
TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL. AN
ADEQUATE MATERIAL HANDLING DEVICE SHOULD BE USED FOR
UNLOADING, MOVING, AND POSITIONING THE SYSTEM.

AC125V-3 Operations Manual....14
5.1 MECHANICAL INSTALLATION
The converters were designed for deck mount installations and as such are provided with ten
mounting holes. Mounting holes have been provided with ½” (12.7mm) diameters; stainless steel
hardware in the range of 3/8” to 7/16” (10-11mm) diameter is required.
The mounting surface should be flat and dimensionally stable to within 1/16” (1.5mm) to prevent
torsional stresses being applied to the structure of the converter. Spacers (shim stock) may be added
between the mounting surface and the converter mounting flanges to adjust the mounting plane. If
the system is to be mounted in a high vibration/shock environment, then the factory must be
consulted concerning the application. Drawings for approved shock mounting assemblies will be
supplied.
The following recommended clearances must be considered during installation for proper operation:
TABLE 2
FOR PROPER:
Operation Service
Front 3” (Intake Airflow) 24” min
Lower Rear Sides 6” (Intake Airflow) 0”
Top (Excluding Keypad) 0” 0”
Rear 3” (Intake Airflow) 0”
Air intake grillwork is provided on the bottom, rear, and lower side panels of the equipment. A total
intake area of 300 in must be provided through a combination of surfaces, excluding that area
2
provided by the bottom. Please contact factory engineers for review of the installation plan if unsure
on any specification or requirement.

AC125V-3 Operations Manual....15
5.1 MECHANICAL INSTALLATION, cont.
FIGURE 2 MECHANICAL OUTLINE

AC125V-3 Operations Manual....16
5.1 MECHANICAL INSTALLATION, cont.
FIGURE 3 CONTROLS

AC125V-3 Operations Manual....17
5.2 ELECTRICAL INSTALLATION
This procedure assumes the physical installation of the converter has been completed. It is the users
responsibility to provide input service over-current protection and disconnect means. Follow the
table below for shore power wiring.
MAXIMUM CURRENTS UNDER LOW-LINE CONDITIONS:
Model AC125V-3
Input Current @ Three Phase, 330-520V 219A
Output Current Refer to Table 1, page 11
All power wiring requires the removal of the front panel and the power cable access cover (cabinet
bottom). This cover is secured with 6 ea 1/4-20” x ½” stainless steel screws. Drill or punch the
appropriate holes for the selected strain reliefs. Re-install the input service panel using the removed
hardware. Place the disconnect switch in the OFF position.
INPUT WIRING MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN FAMILIAR
WITH STANDARD SAFEGUARDS AND PROCEDURES REQUIRED BY THE
INSTALLATION OF THIS TYPE OF EQUIPMENT. POWER MUST BE REMOVED
FROM THE INPUT DISTRIBUTION SYSTEMS SUPPLYING POWER TO THE AC125V-3
PRIOR TO THE START OF THE FOLLOWING STEPS. INPUT POWER MUST BE
SECURED (LOCKED) IN THE OFF (DE-ENERGIZED) STATE UNTIL INSTRUCTED
OTHERWISE BY THIS DOCUMENT. ALSO SECURE IN THE OFF STATE ANY
CIRCUIT BREAKER(S) IN THE SWITCHGEAR PANEL THAT MAY BE SUPPLYING
SHIP’S BUS POWER TO THE CONVERTER OUTPUT TERMINAL BLOCK. FAILURE
TO FOLLOW THESE PROCEDURES CAN RESULT IN DAMAGE TO THE EQUIPMENT,
AND CAN PRESENT THE RISK OF INJURY OR DEATH TO THE INSTALLER OR THE
OPERATOR.

AC125V-3 Operations Manual....18
5.2.1 Input Power Connections
The converter is supplied with compression type terminal blocks for input power connections. These
terminal blocks accept wires in the range of 350MCM to 6AWG. Refer to the applicable standards
for selection of required wire gauge and type.
In two or more cabinet systems, one shore cord is connected to each converter shore power terminal
block.
5.2.2 Output Power Connections
Each system is supplied with compression type terminal blocks for output power connections. These
terminal blocks accept wires in the range of 350MCM to 6AWG. Refer to the applicable standard
for selection of the required wire gauge and type. The output ground wire is to be connected to a
3/8" stud. Please refer to the figure below for additional details.
FIGURE 4 INPUT AND OUTPUT CONNECTIONS

AC125V-3 Operations Manual....19
THE CONVERTER ISOLATES THE OUTPUT POWER FROM THE INPUT
POWER AND EQUIPMENT (SAFETY) GROUNDS SIMILAR TO AN
ISOLATION TRANSFORMER. THE INSTALLER MUST RE-ESTABLISH
THE GROUND REFERENCE FOR THE EQUIPMENT AT TIME OF
INSTALLATION. NEUTRAL AND EQUIPMENT (SAFETY) GROUNDS TO
BE CONNECTED PER ABYC STANDARDS.
Prepare the power cable by removing the outer cable insulation approximately 6". Strip the
insulation back exposing ½" of bare conductor on all three conductors. Insert the prepared cable
and strain relief assembly into the forward hole in the input service panel. Insert the wire ends into
the output terminal block and tighten.
Replace the power cable access cover and front panel using the removed hardware.
Multi-cabinet systems connect outputs at the switchgear panel. It is recommended that connection
be made to the distribution bus through a manuallyoperated disconnect device such as a molded case
switch or circuit breaker (rated for the total system amperage) for ease and safety of service in the
event of converter failure. The internal power contactors manage power control to the distribution
bus applying power through keypad, Auto-Restart, and remote control based commands.

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