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Magnum Dimensions ACLD-40 Owner's Manual

Ac load diversion controller - 4.0kw
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ACLD-40
AC Load Diversion Controller - 4.0kW
Owner's Manual

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Summary of Contents for Magnum Dimensions ACLD-40

  • Page 1 ACLD-40 AC Load Diversion Controller - 4.0kW Owner’s Manual...

  • Page 2: Copyright Notice

    Thank you from all of us at Sensata Technologies for purchasing this ACLD-40 controller. The ACLD-40 (also know as the ACLD) is a product under the Magnum-Dimensions brand from Sensata Technologies. We understand that you have many purchasing options in the marketplace, and we are pleased that you have decided on this product.

  • Page 3: Safety Information

    IMPORTANT PRODUCT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR THE ACLD-40 CONTROLLER THAT SHALL BE FOLLOWED DURING THE INSTALLATION AND OPERATION OF THIS PRODUCT. Before using the ACLD, read all instructions and cautionary markings. Also, be sure to follow the instructions provided for each component of the system.
  • Page 4 CONSIGNES DE SÉCURITÉ IMPORTANTES CONSERVER CES INSTRUCTIONS CE MANUEL CONTIENT DES INSTRUCTIONS IMPORTANTES POUR LE CONTRÔLEUR ACLD-40 AU COURS DE L’INSTALLATION ET FONCTIONNEMENT DU PRODUCT. Before utilisant le ACLD, lire toutes les instructions et mises en garde. Aussi, assurez-vous de suivre les instructions fournies pour chaque composant du système.

  • Page 5: Table Of Contents

    ACLD Startup ..................32 Troubleshooting ..............33 Appendix A – Specifi cations and Optional Equipment ..... 35 ACLD-40 Load Diversion Controller Specifi cations ........35 Regulatory Compliance ................ 36 Optional Equipment and Accessories............36 Appendix B – Warranty and Service ..........37 Limited Warranty ................
  • Page 6 List of Figures Figure 1-1, ACLD Inactive (Utility Power Available) ............2 Figure 1-2, ACLD Active (Utility Power NOT Available) ............3 Figure 1-3, Intake Fan, Status LED, Connection Ports, and Knockouts ........6 Figure 1-4, ON/OFF Power Switch, Info Label and Exhaust Vents ......... 7 Figure 1-5, Wiring Access Cover ..................
  • Page 7 Page vi © 2015 Sensata Technologies...

  • Page 8: Introduction

    1.0 Introduction Congratulations on your purchase of the ACLD-40 (AC Load Diversion - 4.0kW) controller. The ACLD-40 (also know as the ACLD) is designed to be used in an AC coupled system—networked with a MS-PAE Series inverter—to provide three-stage battery charging and to divert any excess power to a resistive load.

  • Page 9: How An Ac Coupled System Works

    (main-panel and critical loads sub-panel), charge the battery system, and feed any surplus renewable energy back into the utility grid. Battery Utility Main Bank Inverter Grid Panel Battery Back-up Section ACLD-40 AC Load Sub- Critical (Secondary) Controller Panel Loads ACLD Section AC Load...

  • Page 10: Figure 1-2, Acld Active (Utility Power Not Available)

    MS-PAE Series inverter will occur, causing it to turn off; which in turn shuts down the entire system (i.e., critical loads and grid-tie inverter turn off). To prevent this from happening, there must be a method of regulating the battery bank and ensuring it is properly charged; this is why the ACLD-40 is needed. Battery Utility...

  • Page 11: Battery Regulation Methods

    Introduction Battery Regulation Methods In an AC-coupled system, there are several methods that are used to regulate the battery voltage, as described below: 1. AC disconnect driven by DC controlled relays: When the battery voltage rises above a maximum setpoint, a battery voltage controlled relay is activated to open the AC connection to the grid-tie inverter.
  • Page 12 6. AC Load Diversion Controller (ACLD-40): When the battery voltage rises above a voltage regulation setpoint, the ACLD-40 begins to send excess current to a dedicated AC diversion load to maintain the battery voltage. When the battery voltage falls below the regulation setpoint, current is no longer sent to the dedicated diversion load.

  • Page 13: Acld Features And Benefi Ts

    Introduction ACLD Features and Benefi ts The ACLD controller is designed with features that allow easy access to wiring and controls. The front of the ACLD controller is equipped with the following (refer to Figure 1-3): Status LED Indicator – this green LED illuminates to provide operation and fault information on the ACLD controller.

  • Page 14: Figure 1-4, On/Off Power Switch, Info Label And Exhaust Vents

    Introduction The right side of the ACLD controller has an information label, exhaust vents and an ON/OFF switch (see Figure 1-4): Information Label – includes model/serial number information, date of manufacture, and specifi cations. See the specifi cations in Appendix A for more information. Exhaust Vents –...

  • Page 15: Installation

    Grid-Tie Comm MS-PAE Series Inverter (GTI) Battery Based Inverter (BBI) Input Input Power (from GTI) (from BBI) ACLD-40 Load Controller Primary Secondary Output Output (to Pri load) (to Sec load) Diversion Load Diversion Load Figure 2-1, Simplifi ed ACLD System Page 8 ©...

  • Page 16: Unpacking And Inspection

    ACLD controller. • The ACLD-40 is limited to 4000 watts continuous and is designed to work with a single MS- PAE Series pure sinewave inverter that has an output voltage of 240VAC. Note: The ACLD-40 cannot be stacked or combined with another ACLD to handle additional power.

  • Page 17: Locating The Acld Controller

    Installation Locating the ACLD Controller Only install the ACLD controller in a location that meets the following requirements: Clean and Dry – The controller should not be installed in an area that allows dust, fumes, insects, or rodents to enter or block the controller’s ventilation openings. This area also must be free from any risk of condensation, water, or any other liquid that can enter or fall on the controller.

  • Page 18: Mounting The Acld Controller

    Installation Mounting the ACLD Controller When mounting the ACLD controller, the surface and the mounting hardware must be capable of supporting at least twice the weight of the unit. To meet regulatory requirements, the ACLD must be mounted in one of the following positions (as shown in Figure 2-3): •...

  • Page 19: Figure 2-4, Acld Dimensions And Side Reference

    Installation Page 12 © 2015 Sensata Technologies...

  • Page 20: General Wiring Requirements

    Installation General Wiring Requirements This section describes the requirements and recommendations for wiring the ACLD controller. Before wiring the controller, carefully read all instructions. Wiring should meet all local codes and standards and be performed by qualifi ed personnel such as a licensed electrician. The NEC (National Electric Code, ANSI/NFPA 70) for the United States and the CEC (Canadian Electrical Code) for Canada provide the standards for safely wiring residential and commercial installations.

  • Page 21: Torque Requirements

    Installation 2.4.4 Wire Size and Overcurrent Protection The wiring must be approved for the application (i.e., residential wiring) and sized per the local electrical safety code requirements to ensure the wire’s ability to safely handle the maximum load current. The wiring must be protected from short circuits and overloads by an overcurrent protection device.

  • Page 22: Acld Terminal Block Connections

    Installation ACLD Terminal Block Connections The ACLD controller has a ten-pole terminal block and a ground busbar to permanently connect the BBI/Battery Based Inverter (e.g., MS-PAE Series), the GTI/Grid-Tie Inverter and any primary or secondary loads (see Figure 2-5). To access and view the terminal block and ground busbar, remove the two Phillips screws holding the AC wiring access cover plate (see Figure 1-5, Item 9).

  • Page 23: Figure 2-6, Acld System Wiring

    Installation Page 16 © 2015 Sensata Technologies...

  • Page 24: Figure 2-7, Ac Wiring From Inverter To Acld

    (from Main Panel) AC NEUTRAL (to Sub-Panel via ACLD) INV HOT 2 OUT (to Sub-Panel via ACLD) AC GROUNDS (to Sub Panel) ACLD-40 Diversion Controller INV OUT (HOT 2) (from inverter H2 Out) INV OUT (HOT 1) (from inverter H1 Out)

  • Page 25: Wiring The Acld

    Installation Wiring the ACLD The following steps are basic guidelines for installing and connecting wiring to and from the ACLD controller. Refer to Figure 2-7 for visual guidance. Note: The instructions below refer to the ACLD’s terminals using the attached label terminology. Wiring the Inverter AC Output to the ACLD 1.

  • Page 26: Acld Load Requirements

    Installation ACLD Load Requirements A diversion load is required to be connected to the ACLD. When the ACLD is activated during a power outage, current from the renewable energy source is used to charge the battery. As the battery becomes charged, the ACLD connects the diversion load to consume any excess power —preventing the battery from being overcharged and damaged.
  • Page 27 Installation 2.9.2 Compatible Diversion Loads Below is a list of compatible loads that may be used with the ACLD. Info: The diversion load must be sized at 110% or larger than the RE source (4800 watts max), and the RE source must be limited to 10% below the continuous power of the battery-based inverter used.

  • Page 28: Connecting The Acld To A Ms-Pae Series Inverter

    Inverter] accessories] REMOTE cable MS-PAE Series Inverter/Charger [Connects to remote from REMOTE (blue) port, ACLD-40 Diversion Controller connects to ACLD from NETWORK (green) port] [Connects from (orange) port to inverter NETWORK (green) port] ACLD / NETWORK cable Figure 2-8, ACLD to Inverter Communications Cable Connection 2.10.1 ACLD/NETWORK Communication Cable...

  • Page 29: Using A Remote Control With The Acld Controller

    However, this feature does not guarantee protection against overcharging the batteries. Therefore, it should only be used as a backup, the ACLD-40 should be used as the primary regulation method to protect the battery bank from being overcharged during utility power failures.

  • Page 30: Operation

    Operation 3.0 Operation ACLD Operation Normally, when utility power is available, the grid-tie inverter in the system converts the renewable energy to AC that works in parallel with the utility to: power the load panels (main panel and sub- panel for critical loads) in the home, charge the battery system, and feed any power—from the renewable energy source—that is not used in the home back into the utility grid.
  • Page 31 Operation The excess current is fi rst diverted to the primary diversion load, which could be sized to absorb the full power output from the renewable energy source without turning off. However, if the primary load is designed or confi gured to turn off (such as a water heater with a thermostat), or sized smaller than required to handle the full diverted current—the battery voltage would begin to rise above its regulated voltage setting.

  • Page 32: Three-Stage Regulation

    Operation Three-Stage Regulation The ACLD uses a three-stage process to help monitor the battery voltage (during Standby mode) and divert current (during Active mode) to help keep the batteries healthy. The three stages: Bulk, Absorb, and Float (see Figure 3-1) provides complete and automatic recharging and monitoring of the batteries without damage due to overcharging.

  • Page 33: Operation Scenarios - Utility Connected

    Operation Operation Scenarios - Utility Connected When utility power is connected, the grid-tie inverter synchronizes to the utility grid and converts the renewable energy to work in parallel with the utility grid to power the main and critical loads in the home.

  • Page 34: Power Flow Scenarios - Utility Not Connected

    Operation Power Flow Scenarios - Utility Not Connected Whenever there is a utility power outage, the MS-PAE Series inverter automatically comes on to start powering the critical loads. Since the grid-tie inverter is connected to the output of the MS- PAE Series inverter, the grid-tie inverter reconnects and starts converting the renewable energy to power the critical loads (see Figure 3-4).

  • Page 35: Figure 3-6, Utility Not Connected - Excess Current Charging Battery Bank

    Operation During a utility power interruption, the main household loads are no longer connected and the utility grid is not able to receive any excess power generated by the renewable energy. This means there may be more current available than the critical loads can consume, causing this excess current to be pushed back thru the AC output of the MS-PAE Series inverter into the battery bank (see Figure 3-6).

  • Page 36: Figure 3-8, Utility Not Connected - Diverting All Power To Primary Load

    Operation Once the battery becomes full, the PWM switch inside the ACLD fully closes to divert all the excess current from the battery to an externally connected primary load (see Figure 3-8). Utility Not Connected – Diverting all Power to Primary Load (ACLD connects primary load to divert all excess current to prevent battery overcharge) Renewable Grid-Tie...

  • Page 37: Power Switch Operation

    Operation Power Switch Operation Power Switch – The power switch on the right side of the ACLD (see Figure 1-2, item 8) is a multi-function switch. It provides the functions of an on/off switch and is a 20-amp circuit breaker that provides overload protection for wiring inside the load controller.

  • Page 38: Operating Modes

    Operation Operating Modes Once the ACLD load controller is powered and turned on, it has three normal operating modes: • Inactive - The ACLD is inactive (not regulating the battery voltage) because utility power is connected to the MS-PAE Series inverter. During the inactive mode, the MS-PAE Series inverter is using the utility grid connected to its input to provide multi-stage charging to the battery bank.

  • Page 39: Acld Startup

    Operation ACLD Startup ON/OFF Switch – The ACLD can be turned on and off by pressing the ON/OFF switch on the right side of the ACLD (refer to Figure 3-10). When the controller’s automatic protection circuit has turned the controller off and the fault is corrected, the ON/OFF switch will need to be cycled off then back on to reset the fault and start the unit.

  • Page 40: Troubleshooting

    Remedy: Check to ensure that the loads are rated for 240 VAC, sized correctly (see Section 2.9.2 on load sizing criteria), and connected to the correct output terminals (see Figure 2-5). The loads should have a resistance between 10-15 ohms (see to Figure 3-11). ACLD-40 Primary Load...
  • Page 41 Troubleshooting Troubleshooting Continued: • Blinks On 5 times then off four seconds - Desat (i.e. Desaturation) Fault; hardware saturation inside the controller has occurred—indicates a possible catastrophic failure. Remedy: This fault requires a reset of the ACLD. Press the ON/OFF switch on the side of the ACLD controller to remove power to the unit, and then press the ON/OFF switch again to restore power.

  • Page 42: Appendix A - Specifi Cations And Optional Equipment

    Appendix A – Specifi cations and Optional Equipment Appendix A – Specifi cations and Optional Equipment A-1 ACLD-40 Load Diversion Controller Specifi cations Electrical Specifi cations Input Voltage (from inverter & grid) 240 VAC ± 10% Output Voltage (to load)

  • Page 43: Regulatory Compliance

    AC coupled system. Even though used in an AC coupled system—and normally is connected to the utility grid—the ACLD-40 is not a grid- interactive (also known as utility-interactive) device and does not have the capability to export (or sell) power back into the utility grid.

  • Page 44: Appendix B - Warranty And Service

    1. The limited warranty for the product extends for 36 months beginning from the product’s original date of purchase. Note: The normal 3-year warranty on this ACLD-40 is extended to 5 years if it was ordered with and installed on one of the MMP or MP enclosure systems. A proof-of-purchase is required at the time of repair/service showing that the ACLD diversion controller and the MP or MMP panel system were purchased at the same time.
  • Page 45 Notes: Page 38 © 2015 Sensata Technologies...
  • Page 46 Magnum-Dimensions Products Manufactured by: Sensata Technologies 2211 West Casino Rd. Everett, WA 98204 Phone: 425-353-8833 Fax: 425-353-8390 Web: www.magnum-dimensions.com/ ACLD-40 Owner’s Manual (PN: 64-0062 Rev A)

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