ASEA AC55V-3 User manual

Operations Manual
for the ASEA Power Systems
Model AC55V-3, AC63V-3,
And AC75V-3
3 Phase Yacht Power Converters
P/N 605051, Revision B
Issued 10/2/2009

AC55V-3 / AC63V-3 / AC75V-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.

AC55V-3 / AC63V-3 / AC75V-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 models:
AC55V-3 55kVA 3 Phase Yacht Power Converter
AC63V-3 63kVA 3 Phase Yacht Power Converter
AC75V-3 75kVA 3 Phase Yacht Power Converter
Please note that each converter is capable of being paralleled for higher power applications.
The Model AC55V-3 can be paralleled to produce the following models:
AC110V-3/2 110kVA 3 Phase Yacht Power Converter
AC165V-3/3 165kVA 3 Phase Yacht Power Converter
AC220V-3/4 220kVA 3 Phase Yacht Power Converter
The Model AC63V-3 can be paralleled to produce the following models:
AC125V-3/2 125kVA 3 Phase Yacht Power Converter
AC190V-3/3 190kVA 3 Phase Yacht Power Converter
AC250V-3/4 250kVA 3 Phase Yacht Power Converter
The Model AC75V-3 can be paralleled to produce the following models:
AC150V-3/2 150kVA 3 Phase Yacht Power Converter
AC225V-3/3 225kVA 3 Phase Yacht Power Converter
AC300V-3/4 300kVA 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]
http://www.aseapower.com

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....4
TABLE OF CONTENTS
CERTIFICATION ...........................................................................................................................2
WARRANTY ..................................................................................................................................2
1 USING THIS MANUAL.....................................................................................................3
2 SAFETY NOTICES.............................................................................................................6
3 INTRODUCTION TO THE CONVERTERS.....................................................................8
4 SPECIFICATIONS............................................................................................................10
4.1 ELECTRICAL SPECIFICATIONS ......................................................................10
4.1.1 Input Service..............................................................................................10
4.1.2 Output Service ...........................................................................................10
4.1.3 Control, Metering, and Status....................................................................12
4.2 PHYSICAL SPECIFICATIONS ...........................................................................12
4.2.1 Mechanical ............................................................................................12
4.2.2 Environmental............................................................................................12
5 INSTALLATION ..............................................................................................................13
5.1 MECHANICAL INSTALLATION.......................................................................14
5.2 ELECTRICAL INSTALLATION.........................................................................17
5.2.1 Input Power Connections...........................................................................18
5.2.2 Output Power Connections........................................................................18
5.2.3 Seamless Transfer Connections.................................................................20
5.2.4 Multi-Cabinet.............................................................................................23
6 OPERATION.....................................................................................................................24
6.1 POWER TURN-ON PROCEDURE......................................................................24
6.1.1 Systems Not Equipped With The Seamless Transfer Option....................26
6.1.2 Systems Equipped With The Seamless Transfer Option...........................27
6.2 MULTI-CABINET TURN-ON PROCEDURE.....................................................29
6.3 AUTO-RESTART FEATURE ..............................................................................30
6.3.1 Operation ...................................................................................................31
6.4 TURN-OFF PROCEDURE ...................................................................................32
6.4.1 Systems Not Equipped With The Seamless Transfer Option....................32
6.4.2 Systems Equipped With The Seamless Transfer Option...........................33
6.5 REMOTE COMMUNICATION ...........................................................................34

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....5
7 SOFTWARE FEATURES.................................................................................................39
7.1 GENERAL.............................................................................................................39
7.2 LOAD MANAGEMENT.......................................................................................39
7.3 LOAD MANAGEMENT OPERATION...............................................................41
7.3.1 Shore Cord Alarm, Single, Master, and Slave converters.........................41
7.3.2 Shore Cord Setup, Single, Master, or Slave Converters............................42
7.3.3 Load Sharing, Slave converters with Shore Cord Management Option....43
7.3.4 Voltage Droop, Single or Master Converters ............................................45
7.3.5 Automatic Transfer to Generator, Single or Master Converters (Seamless
Transfer installed)......................................................................................46
7.3.6 Quick Setup of Shore Cord Alarm, Single, Master, or Slave Converters..47
7.3.7 Expert Load Sharing Use, Paralleled Converters ......................................48
7.4 GENERATOR FREQUENCY ANALYSIS..........................................................49
7.5 CONVERTER OUTPUT IMPEDANCE CONTROL...........................................49
7.6 AGC CONTROL ...................................................................................................50
7.7 kW-HOUR METER AND MAXIMUM POWER LEVEL DISPLAY.................51
7.8 CONVERTER OUTPUT VOLTAGE CONTROL...............................................52
7.9 EVENT LOG.........................................................................................................53
8 DIAGNOSTICS.................................................................................................................55
9 CALIBRATION ................................................................................................................57
10 MAINTENANCE..............................................................................................................59
11 INTERNATIONAL POWER FORM REFERENCE........................................................60
FIGURES
1 SYSTEM BLOCK DIAGRAM...........................................................................................8
2 MECHANICAL OUTLINE...............................................................................................15
3 CONTROLS ......................................................................................................................16
4 INPUT AND OUTPUT CONNECTIONS........................................................................18
5 SEAMLESS TRANSFER PCB CONNECTIONS............................................................22
6 FRONT PANEL CONTROLS...........................................................................................24
7 RS-232C PINOUT.............................................................................................................35
8 STATUS WORD BIT DEFINITIONS..............................................................................56

AC55V-3 / AC63V-3 / AC75V-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 INTHIS 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.

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....7
THIS EQUIPMENT CONTAINS HIGH ENERGY, LOW IMPEDANCECIRCUITS!
LETHALPOTENTIALSARECONTAINEDWITHINTHESYSTEMEVENWHEN
IT IS APPARENTLY NOT OPERATING.
CAREMUSTBEEXERCISEDWHEN SERVICINGTHISEQUIPMENTINORDER
TO PREVENT SERIOUS OPERATOR INJURY OR EQUIPMENT DAMAGE.
DO NOT WORK ON OR OPERATE THIS EQUIPMENT UNLESS YOU ARE
FULLY QUALIFIED TO DO SO. NEVER WORK ALONE.
THEEQUIPMENT IS NOTIGNITION RATED, ITMUSTNOTBEOPERATED IN
AREAS WHERE COMBUSTIBLE GASES MAY ACCUMULATE.
OBSERVE THE FOLLOWING WHEN SERVICE AND MAINTENANCE ARE
REQUIRED:
REMOVE ALL JEWELRY FROM ARMS AND NECK WHEN SERVICING THIS
EQUIPMENT. THIS PREVENTS THE POSSIBILITYOFSHORTING THROUGH
THE JEWELRY, OR ELECTROCUTION OF THE OPERATOR.
WEARSAFETYGLASSESWHENSERVICINGTHISEQUIPMENTTOPREVENT
EYEINJURYDUETOFLYING PARTICLES CAUSED BY ACCIDENTAL SHORT
CIRCUIT CONDITIONS.
DONOTREMOVEANYPANELSORCOVERS WITHOUTFIRSTOPENINGALL
SHORE POWER AND SWITCHGEAR CIRCUIT BREAKERS DISTRIBUTING
POWER TO AND FROM THE CONVERTER, AND THEN REMOVING THE
INPUT SERVICE.
SERVICE SHOULD BE REFERRED TO PERSONNEL AUTHORIZED BY THE
FACTORY TO SERVICE THIS EQUIPMENT.

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....8
3 INTRODUCTION TO THE CONVERTERS
Each model is a high performance Yacht Power Converter utilizing dual-conversion technology.
The systems will accept any three phase input service with a frequency between 40-70Hertz, and a
voltage between 170-520VAC.
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 forACpowerconversion,and was chosen for
each 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.
FIGURE 1 SYSTEM BLOCK DIAGRAM

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....9
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
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, each 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.

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....10
4 SPECIFICATIONS
4.1 ELECTRICAL SPECIFICATIONS
Parameter AC55V-3 AC63V-3 AC75V-3
4.1.1 Input Service
Input Power Form Three Phase Three Phase Three Phase
Input Voltage Range 170-520VAC 170-520VAC 170-520VAC
Input Frequency Range 40-70 Hertz 40-70 Hertz 40-70 Hertz
Input Current, Max. Three Phase 160 ARMS 170 ARMS 209 ARMS
Input Current, Soft Start, Max. 20 ARMS 20 ARMS 20 ARMS
Input Current Distortion <8% THD @ rated load <8% THD @ rated load <8% THD @ rated load
Input Power Factor >0.98 @ rated load >0.98 @ rated load >0.98 @ rated load
4.1.2 Output Service
Output Power Rating 55kVA @ 0.85 p.f. 63kVA @ 0.85 p.f. 75kVA @ 0.85 p.f.
Output Power Form Three-Phase 120/208VAC, 127/220VAC, 220/380 VAC,230/400 VAC, 240/416 VAC,
254/440 VAC,and 277/480VAC
Output Frequency 50 or 60 Hertz 50 or 60 Hertz 50 or 60 Hertz
Output Frequency Accuracy 0.01% 0.01% 0.01%
Output Voltage Distortion < 1% THD < 1% THD < 1% THD
Output Voltage Line Regulation 0.50% 0.50% 0.50%
Output Voltage Load Regulation 1.0% 1.0% 1.0%
Output Voltage Response Time 0.20 msec. 0.20 msec. 0.20 msec.
Output Current, Continuous Refer to Table 1 on the following page for basic ratings.
Output Current, Peak 625% of cont. rating 540% of cont. rating 460% of cont. rating
Output Current, Surge 435% of cont. rating 380% of cont. rating 320% of cont. rating
Conversion Efficiency 92% @ rated load 93% @ rated load 93% @ rated load

AC55V-3 / AC63V-3 / AC75V-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 AC55V-3 AC63V-3 AC75V-3
3Ø, 277/480VRMS
66ARMS/Ø 76ARMS/Ø 90ARMS/Ø
3Ø, 254/440VRMS 72ARMS/Ø 83ARMS/Ø 98ARMS/Ø
3Ø, 240/416VRMS 76ARMS/Ø 88ARMS/Ø 104ARMS/Ø
3Ø, 230/400VRMS 80ARMS/Ø 91ARMS/Ø 109ARMS/Ø
3Ø, 220/380VRMS 83ARMS/Ø 95ARMS/Ø 114ARMS/Ø
3Ø, 127/220VRMS 144ARMS/Ø 165ARMS/Ø 197ARMS/Ø
3Ø, 120/208VRMS 152ARMS/Ø 175ARMS/Ø 209ARMS/Ø

AC55V-3 / AC63V-3 / AC75V-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 AC55V-3 AC63V-3 AC75V-3
4.2.1 Mechanical
Height 65.13"/165cm 65.13"/165cm 65.13"/165cm
Width, Enclosure 25"/63.5cm 25"/63.5cm 25"/63.5cm
Depth 20"/50.8cm 20"/50.8cm 20"/50.8cm
Weight 1240lbs/562.5kg 1240lbs/562.5kg 1240lbs/562.5kg
4.2.2 Environmental
Ambient Temperature Range 0-50C non-condensing
Air Exchange Rate 1000CFM

AC55V-3 / AC63V-3 / AC75V-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 minimumclearances provided in Table2. Ensuretheroom/compartment has adequate
ventilation and cooling. The thermal load presented by the converter will be substantial and
approximately13,500BTU/Hratmaximum continuous load for the AC55V-3; 13,725BTU/Hr
for the AC63V-3; and 16,320 BTU/Hr for the AC75V-3.
THE CONVERTER IS HEAVY, WEIGHING UP TO 1240lbs. DEPENDING
ON THE OPTIONS INSTALLED. EXTREME CAUTION MUST BE
EXERCISED IN HANDLING AND INSTALLATION TO AVOID
EQUIPMENT DAMAGE OR INJURY TO PERSONNEL. AN ADEQUATE
MATERIAL HANDLING DEVICE SHOULDBE USED FOR UNLOADING,
MOVING, AND POSITIONING THE SYSTEM.

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....14
5.1 MECHANICAL INSTALLATION
The converters were designed for deck mount installations and as such are provided with six
mounting holes, three per side. 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 (shimstock) 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 12” (User access) 24” min
Lower Rear Sides 6” (Intake Airflow) 0”
Top 0” 14”
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 in2must be provided through a combination of surfaces, excluding that area
provided by the bottom. Please contact factory engineers for review of the installation plan if unsure
on any specification or requirement.

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....15
5.1 MECHANICAL INSTALLATION, cont.
FIGURE 2 MECHANICAL OUTLINE

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....16
5.1 MECHANICAL INSTALLATION, cont.
FIGURE 3 CONTROLS

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....17
5.2 ELECTRICAL INSTALLATION
This procedure assumes the physical installation of the converter has been completed. It is the
user’s 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 AC55V-3 AC63V-3 AC75V-3
Input Current
Three Phase, 170-290V 180A 200A 230A
Three Phase, 330-520V 90A 105A 125A
Output Current Refer to Table 1, page 11
All power wiring requires the removal of the front panel, the interior safety cover, 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 MUSTBE PERFORMED BY A QUALIFIED ELECTRICIANFAMILIAR
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
AC75V/AC90V/AC100V-3PRIORTOTHESTARTOFTHEFOLLOWINGSTEPS. INPUT
POWERMUSTBESECURED(LOCKED)INTHEOFF (DE-ENERGIZED)STATEUNTIL
INSTRUCTED OTHERWISE BY THIS DOCUMENT. ALSO SECURE IN THE OFF
STATE ANY CIRCUIT BREAKER(S) IN THE SWITCHGEAR PANEL THAT MAY BE
SUPPLYINGSHIP’SBUSPOWER TOTHECONVERTEROUTPUTTERMINALBLOCK.
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.

AC55V-3 / AC63V-3 / AC75V-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 isconnected 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 4 on the previous page for additional detail.
FIGURE 4 INPUT AND OUTPUT CONNECTIONS

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....19
THECONVERTERISOLATESTHEOUTPUT POWER FROMTHE INPUT
POWER AND EQUIPMENT (SAFETY) GROUNDS SIMILAR TO AN
ISOLATIONTRANSFORMER. THE INSTALLER MUSTRE-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 manually operated 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,andremotecontrol based commands.

AC55V-3 / AC63V-3 / AC75V-3 Operations Manual....20
5.2.3 Seamless Transfer Connections
If the Seamless Transfer Option was ordered with the system, connections must be made between
the generator and the converter. These connections are used by the converter to successfully manage
the seamless transfer operation and are comprised of control, signal, and feedback functions. These
connections are only required on the Master cabinet of a multi-cabinet installation. The use of 14-
18AWG wire is recommended for signal and control wiring.
Figure 5 on page 22 depicts the power and signal connections for a typical installation. A single
generator’s wiring is shown for clarity.
Contact the factory for complete and specific system wiring drawings. These can be supplied
in either printed or electronic format.
A motorized circuit breaker is used for generator transfer in the example, with line voltage operated
actuator coils. The control signals provided by the converter are momentary. The control pulse
width for the momentary control signals is 0.6 seconds for both the open and close commands. The
contacts used for generator control are rated for a maximumof 8A @250VAC or 5A @24VDC. The
generator contactor or circuit breaker must be equipped with an auxiliary switch contact set--closed
when the main contacts are closed.
The generator voltage sense wires are used by the converter to match its output voltage, frequency,
and phase angle to the generator’s and should be fused at the generator.