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