ASEA AC90LC-3 User manual

Operations Manual
for the ASEA Power Systems
Model AC90LC-3, AC100LC-3, and AC125LC-3,
3 Phase Shore Power Converters
(for Motor Yachts)
P/N 617050 Rev. A
Issued 7/19/2013

AC90LC-3, AC100LC-3, and AC125LC-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 fromdefects inmaterialand workmanship. For aperiodof
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 operatedinamanner 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.

AC90LC-3, AC100LC-3, and AC125LC-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:
AC90LC-3 90kVA 3 Phase Shore Power Converter
AC100LC-3 100kVA 3 Phase Shore Power Converter
AC125LC-3 125kVA 3 Phase Shore Power Converter
Please note that each converter is capable of being paralleled for higher power applications.
The Model AC90LC-3 can be paralleled to produce the following models:
AC180LC-3/2 180kVA 3 Phase Shore Power Converter
AC270LC-3/3 270kVA 3 Phase Shore Power Converter
AC360LC-3/4 360kVA 3 Phase Shore Power Converter
Please note that each converter is capable of being paralleled for higher power applications.
The Model AC100LC-3 can be paralleled to produce the following models:
AC200LC-3/2 200kVA 3 Phase Shore Power Converter
AC300LC-3/3 300kVA 3 Phase Shore Power Converter
AC400LC-3/4 400kVA 3 Phase Shore Power Converter
The Model AC125LC-3 can be paralleled to produce the following models:
AC250LC-3/2 250kVA 3 Phase Shore Power Converter
AC375LC-3/3 375kVA 3 Phase Shore Power Converter
AC500LC-3/4 500kVA 3 Phase Shore Power Converter
AC625LC-3/5 625kVA 3 Phase Shore Power Converter
AC750LC-3/6 750kVA 3 Phase Shore Power Converter
It is important that the operator reads this manual prior to installing and operating the converter. A
thorough understandingof the information covered in this manual is required forproper 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. 92649-1604
Phone [phone]
FAX [phone]
Web http://www.aseapower.com

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....4
TABLE OF CONTENTS
WARRANTY ..................................................................................................................................2
1 USING THIS MANUAL.....................................................................................................3
2 SAFETY NOTICES.............................................................................................................6
3 INTRODUCTION TO THE CONVERTERS.....................................................................8
4 SPECIFICATIONS............................................................................................................11
4.1 ELECTRICAL SPECIFICATIONS.......................................................................11
4.1.1 Input Service..............................................................................................11
4.1.2 Output Service ...........................................................................................12
4.1.3 Control, Metering, and Status....................................................................12
4.2 PHYSICAL SPECIFICATIONS............................................................................13
4.2.1 Mechanical ............................................................................................13
4.2.2 Environmental............................................................................................13
4.2.3 Coolant Requirements................................................................................13
5 INSTALLATION...............................................................................................................15
5.1 MECHANICAL INSTALLATION .......................................................................16
5.2 WATER LINE PLUMBING..................................................................................19
5.3 ELECTRICAL INSTALLATION..........................................................................21
5.3.1 Input Power Connections...........................................................................22
5.3.2 Output Power Connections........................................................................22
5.3.3 Grounding..................................................................................................24
5.3.4 Multi-Cabinet Connections........................................................................25
5.3.5 Seamless Transfer Connections.................................................................26
5.3.6 Other Optional Connections ......................................................................27
6 OPERATION.....................................................................................................................28
6.1 POWER TURN-ON PROCEDURE......................................................................28
6.1.1 Systems Not Equipped With The Seamless Transfer Option....................30
6.1.2 Systems Equipped With The Seamless Transfer Option...........................31
6.2 MULTI-CABINET TURN-ON PROCEDURE.....................................................33
6.3 AUTO-RESTART FEATURE ..............................................................................34
6.3.1 Operation....................................................................................................35
6.4 TURN-OFF PROCEDURE...................................................................................36
6.4.1 Systems Not Equipped With The Seamless Transfer Option....................36
6.4.2 Systems Equipped With The Seamless Transfer Option...........................37
6.5 REMOTE COMMUNICATION ...........................................................................38
6.5.1 RS-232C/SCPI...........................................................................................39
6.5.2 RS-485/Modbus.........................................................................................40

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....5
7 SOFTWARE FEATURES.................................................................................................43
7.1 GENERAL.............................................................................................................43
7.2 LOAD MANAGEMENT.......................................................................................43
7.3 LOAD MANAGEMENT OPERATION...............................................................45
7.3.1 Shore Cord Alarm, Single, Master, and Slave converters .........................45
7.3.2 Shore Cord Setup, Single, Master, or Slave Converters............................46
7.3.3 Voltage Droop, Single or Master Converters.............................................47
7.3.4 Automatic Transfer to Generator, Single or Master Converters (Seamless
Transfer installed)......................................................................................48
7.3.5 Quick Setup of Shore Cord Alarm, Single, Master, or Slave Converters..49
7.4 GENERATOR FREQUENCY ANALYSIS..........................................................50
7.5 CONVERTER OUTPUT IMPEDANCE CONTROL...........................................50
7.6 AGC CONTROL...................................................................................................51
7.7 kW-HOUR METER AND MAXIMUM POWER LEVEL DISPLAY.................52
7.8 CONVERTER OUTPUT VOLTAGE CONTROL...............................................53
7.9 EVENT LOG .........................................................................................................54
8 DIAGNOSTICS.................................................................................................................56
9 CALIBRATION.................................................................................................................59
10 MAINTENANCE ..............................................................................................................61
11 MSDS SHEET, COOLANT OIL.......................................................................................62
12 INTERNATIONAL POWER FORM REFERENCE........................................................69
FIGURES
1 SYSTEM BLOCK DIAGRAM ...........................................................................................8
2 OIL-TO-WATER COOLING SYSTEM BLOCK DIAGRAM.........................................10
3 OUTPUT DERATING ......................................................................................................14
4 MECHANICAL OUTLINE, FRONT AND SIDE ............................................................17
5 MECHANICAL OUTLINE, BASE...................................................................................18
6 WATER LINE INSTALLATION......................................................................................20
7 INPUT AND OUTPUT CONNECTIONS ........................................................................23
8 N/A.........................................................................................................................................
9 FRONT PANEL CONTROLS...........................................................................................28
10 RS-232C PINOUT.............................................................................................................39
11 RS-485 CONNECTIONS..................................................................................................40
12 STATUS WORD BIT DEFINITIONS ..............................................................................58

AC90LC-3, AC100LC-3, and AC125LC-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
carefullyand use professional skills and prudent care when performing the actions described bythe
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.

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....7
THIS EQUIPMENT CONTAINS HIGH ENERGY, LOW IMPEDANCE CIRCUITS!
LETHAL POTENTIALS ARE CONTAINED WITHIN THE SYSTEM EVEN WHEN IT
APPEARS TO NOT BE OPERATING.
CARE MUST BE EXERCISED WHEN SERVICING THIS EQUIPMENT IN ORDER 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.
THE EQUIPMENT IS NOT IGNITION RATED,ITMUSTNOT BE OPERATEDINAREAS
WHERE COMBUSTIBLE GASES MAY ACCUMULATE.
THIS EQUIPMENT CONTAINS HYDRAULIC FITTINGS AND EMPLOYS A COOLANT
OIL. DO NOT ATTEMPT TO SERVICE THE HYDRAULIC SYSTEM WITHOUT THE
ASSISTANCE OF FACTORY AUTHORIZED PERSONNEL.
THE HEAT EXCHANGER HAS WATERSYSTEMTHAT IS UNDER PRESSURE. NEVER
OPEN THE WATER CONNECTIONS UNLESS THE WATER SYSTEM HAS BEENSHUT
OFF AT IN THE SUPPLY AND RETURN LINES.
OBSERVETHEFOLLOWINGWHENSERVICEANDMAINTENANCEAREREQUIRED:
REMOVE ALL JEWELRY FROM ARMS AND NECK WHEN SERVICING THIS
EQUIPMENT. THIS PREVENTS THE POSSIBILITY OF SHORTING THROUGH THE
JEWELRY, OR ELECTROCUTION OF THE OPERATOR.
WEAR SAFETY GLASSES WHEN SERVICING THIS EQUIPMENT TO PREVENT EYE
INJURY DUE TO FLYING PARTICLES CAUSED BY ACCIDENTAL SHORT CIRCUIT
CONDITIONS.
DONOTREMOVEANYPANELSORCOVERSWITHOUTFIRSTOPENINGALLSHORE
POWER AND SWITCHGEAR CIRCUIT BREAKERSDISTRIBUTING POWER TO AND
FROM THE CONVERTER, AND THEN REMOVING THE INPUT SERVICE.
SERVICESHOULDBEREFERREDTOPERSONNELAUTHORIZEDBYTHEFACTORY
TO SERVICE THIS EQUIPMENT.

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....8
3 INTRODUCTION TO THE CONVERTERS
The AC90LC-3, AC100LC-3, and AC125LC-3 are high performance Shore Power Converters.
These models are internallyoil-cooled, where a customer-managed water cooling loop carries away
heat energy from thecooling oil via a base-mounted heat exchanger. Themainoilreservoirissealed
to the point that it is splash-proof; therefore, the converter must remain vertical at all times. As a
result, these converters are intended for motor yachts and cannot be used with sailing yachts,
catamarans, or any other vehicle that may spend time heeled.
These converters will accept any three phaseinputservice with afrequencybetween40-70Hertz,and
a voltage between 330-520VAC. The output power form has beenprogrammed at the factoryfor the
voltage and frequency required by your yacht.
Dual-conversion technologyis the preferred techniquefor AC power conversion,and was chosenfor
the system design. In this technology, the shore power service isisolatedbythetransformerandthen
converted to DC power by the DC power supply module. 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

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....9
Being a converter designed from the ground up specificallyfor the yachtingindustry, 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 front and top access to the system.
Three lightweight power modules can beremoved and replaced through thefront and toppanels 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 inputserviceduring maintenanceand 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.

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....10
System cooling is accomplished through a primary, oil-to-water based exchange system as well as a
supplemental forced-air cooling system. The main isolation transformer and output filter inductors
are immersed in an oil which then circulates through coolingplates where input rectifiers andoutput
transistors (IGBTs) are mounted. The oil further circulates through aliquid-to-liquidheat exchanger
where the oil transfers its heat energy into the customer-supplied coolant water also circulating
through the heat exchanger. These heat exchangers intended for fresh chilled water a water/coolant
mix.
FIGURE 2 OIL-TO-WATER COOLING SYSTEM BLOCK DIAGRAM

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....11
4 SPECIFICATIONS
4.1 ELECTRICAL SPECIFICATIONS
Parameter AC90LC-3 AC100LC-3 AC125LC-3
4.1.1 Input Service
Input Power Form Three Phase Three Phase Three Phase
Input Voltage Range 330-520VAC 330-520VAC 330-520VAC
Input Frequency Range 40-70 Hertz 40-70 Hertz 40-70 Hertz
Input Current, Max. Three Phase 136 ARMS 151 ARMS 189 ARMS
Input Current, Soft Start, Max. 64 ARM 64 ARMS 64 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 90kVA @ 0.85 p.f. 100kVA @ 0.85 p.f. 125kVA @ 0.80 p.f.
Output Power Form Three-Phase 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 page 12 for basic ratings.
Output Current, Peak 270% of cont. rating 270% of cont. rating 220% of cont. rating
Output Current, Surge 150% of cont. rating 150% of cont. rating 150% of cont. rating
Conversion Efficiency 93% @ rated load 93% @ rated load 94% @ rated load

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....12
4.1 ELECTRICAL SPECIFICATIONS,cont.
4.1.2 Output Service, cont.
Table 1 - Output Current, Rated Continuous RMS
Output Form
AC90LC-3
AC100LC-3
AC125LC-3
3Ø, 277/480VRMS
108ARMS/Ø
120ARMS/Ø
150ARMS/Ø
3Ø, 254/440VRMS
118ARMS/Ø
131ARMS/Ø
164ARMS/Ø
3Ø, 240/416VRMS
125ARMS/Ø
139ARMS/Ø
174ARMS/Ø
3Ø, 230/400VRMS
130ARMS/Ø
145ARMS/Ø
181ARMS/Ø
3Ø, 220/380VRMS
136ARMS/Ø
152ARMS/Ø
189ARMS/Ø
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
Converter Power Control Membrane Switch, Output ON/OFF Control
Ship’s Power Control Membrane Switch, 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

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....13
4.2 PHYSICAL SPECIFICATIONS
4.2.1 Mechanical
Parameter
Height 47.00"/119.4cm
Width, Enclosure 26.50"/67.31cm
Depth 34.36"/87.27cm
Weight AC90LC/AC100LC/AC125LC 1916lbs / 869kg
4.2.2 Environmental
Ambient Temperature Range 0-45C non-condensing (see derating chart on the following
page)
Air Exchange Rate 200CFM
4.2.3 Coolant Requirements
Water Flow Rate * 4-10 GPM range (minimum and maximum, respectively)
Coolant Flow Rate * 8-16 GPM range (minimum and maximum, respectively)
Water/Coolant Flow Min. Rate * 4 + (4 * Percent Coolant)
e.g. 100% coolant mix, 4 + (4 *1.00) = 8 GPM
50% coolant mix, 4 + (4 *0.50) = 6 GPM
Water/Coolant Temperature * 4-10°C for full output power capability. See derating chart on the
next page for operation at other temperatures.
Water/Coolant Pressure 4 bar maximum
* The minimum required water flow rate and temperature combination curve, along with the two
derating curves, are used to specificallyaddress oneoranother non-optimal coolantsupplycondition.
If the shipyard or customer expects multiple non-optimal conditions to exist, the factory must be
contacted. For example, if elevated coolant temperatures are too be used while also operating with
an elevated ambient temperature, the factory can estimate the combined derating that applies.

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....14
4.1 ELECTRICAL SPECIFICATIONS, cont.
FIGURE 3 OUTPUT DERATING

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....15
5 INSTALLATION
The installation section is divided into three parts. The first section will cover mechanical
installation, the second section water line plumbing, and final section 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. Contact the factory immediately if any
damage or anycoolant oil leak is encountered. Verifythat 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 ship’s chilled water supply dedicated to the converter’s heat exchanger has
sufficient thermal capacity to accommodate the thermal load presented by the converter. It
will be approximately the following at maximum continuous load: 21,000 BTU/Hr for the
AC90LC-3, AC100LC-3, or AC125LC-3.
Ensure the installation room or compartment has adequate ventilation and cooling. The
thermal load presented by the converter through air exchange will be approximately the
following at maximum continuous load: 800 BTU/Hr for the AC90LC-3, AC100LC-3, or
AC125LC-3.
THE CONVERTERS ARE HEAVY, WEIGHING UP TO 1916lbs DEPENDING
UPON MODEL AND INSTALLED OPTIONS. 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. THE CONVERTERS MUST STAY IN A
COMPLETELY VERTICAL ORIENTATION OR OIL LEAKAGE WILL OCCUR.

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....16
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 1/2" (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) maybeadded
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.
Due to the available variations in the LC series cabinet configurations, please refer also to available
Installation and Mounting Drawing for clearance and ventilation paths.
Table 2 FOR PROPER:
Operation Service
Front 4" (Exhaust airflow) 24" min
Top 0" 6"
Rear 2" (Intake airflow) 0"
Air intake louvers are provided at the rear-top area of the converter. Air exhaust louvers are
provided at the front-top area of the converter. Please contact factory engineers for review of the
installation plan if unsure about any specification or requirement.
The converter must remain vertical at all times due to the coolant oil reservoir characteristics.
Movement may only occur with the converter in the vertical orientation.

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....17
5.1 MECHANICAL INSTALLATION, cont.
FIGURE 4 MECHANICAL OUTLINE, FRONT AND SIDE

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....18
5.1 MECHANICAL INSTALLATION, cont.
FIGURE 5 MECHANICAL OUTLINE, BASE

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....19
5.2 WATER LINE PLUMBING
All water line connections are to be made using 1/2" NPT fittings. Use Teflon sealant to
ensure that no leakage will occur.
Isolation valves must be installed locally for maintenance purposes, and so that shutoff can
occur in the event of a water leak.
The ASEA-supplied Flow Control Solenoid must be installed and located within 24" of the
bottom right front corner of the converter as dictated by the supplied control cable length.
The ASEA-supplied Flow Control Solenoid is directional and must be installed in
accordance with the marking in the brass body at the inlet side.
Condensation may occur on the heat exchanger body based on humidity levels in the
environment. The installer should design the area around the converter accordingly. If
insolation is added to the exchanger, DO NOT insulate the body of the Flow Control
Solenoid.
To ensure that no air becomes trapped in the heat exchanger unit, route the water return line
above the level of the heat exchange unit before connection to the return main.
The heat exchanger unit is constructedof 90/10 cuprous nickel. There is azinc pencil anode
located on the heat exchanger unit end bell.
No maintenance need be performed on the heat exchanger unit other than periodic checking
of the zinc pencil anode when used in a chilled, fresh water system.
A water flow rate greater than 16 GPM (Gallons Per Minute) is wasteful and can accelerate
water erosion of the heat exchange unit’s cuprous nickel piping.

AC90LC-3, AC100LC-3, and AC125LC-3 Operations Manual....20
5.2 WATER LINE PLUMBING, cont.
FIGURE 6 WATER LINE PLUMBING