Home

64-00062 Rev A (ACLD-40) (Final).indd

Contents

1. Critical a itch Battery MS PAE Series Loads ae Bank Inverter Battery Full Primary Secondary A MagNet Control Main AA LA epe UM Loads lt Load Load Not powered Not powered Note When the MS PAE Series inverter is connected to the utility and charging the battery the ALCD is Inactive Figure 3 3 Utility Connected Additional Power Provided by the Utility Grid Page 26 2015 Sensata Technologies Operation 3 4 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 Utility Not Connected RE Powers Critical Loads Critical loads consume all the Renewable Energy Renewable Grid Tie Energy Inverter ACLD Controller Standby bia C C FFE H y j 7 AAA EE 7 A Critical itch Battery MS PAE Series Loads EE Bank Inverter J Relay
2. EEEH Battery Nominal fU Primary Secondary MagNet Control Load Load Not Powered Not Powered Note When the utility power is lost Main Z Utility and the MS PAE Series inverter is Household Grid Power inverting the ACLD is in Standby Loads mode and ready to regulate the charge current to the battery Figure 3 4 Utility not Connected RE Powers Critical Loads During occasions when the renewable energy is less than the power required by the critical loads i e PV system at night the additional power is provided by the MS PAE Series inverter using power from the battery bank see Figure 3 5 Utility Not Connected Additional Power Provided to Critical Loads Power to critical loads greater than available from the Renewable Energy Renewable Grid Tie Energy Inverter ACLD Controller NER Standby UP Critical Battery MS PAE Series Loads Bank Inverter lt DCI Rela Battery y Decreasing s l ar Primary Secondary MagNet Control me Load Load Not Powered Not Powered Main Household Loads Utility Grid Power Note When the utility power is los
3. e 110 oooQ joeuuoo siq J MOd AUN unim W93S S a712v 9 z 21n614 J29uu09sIq AeJJV Ad Ue AJo3eg J93J9AU un Pun Pun LEE E op P P P us ET Fr bi L uu uO uxO u O uxO uxO ux O uO un Duu jaued AWN wleW jeued qns Spe07 122119 Pur puc pue MLO uno abes ses O One oz oz z Ole qe i i JOUSAUI Jaap DADEJAQUI AIIIN e ueuuoJlad d gt 6 ZHO9O OVAOvVC IM Ln L E 5 yia IIS O al TE 013U07 29joulay 9 e CO 9 EM BAN SS j ou u oe c1 11 o o eJnsopu3 dININ UO J93J9AU 1Vd SW 11 avo1 AuvaNooas ot c1 avo1 AuvaNoos
4. Grid Tie MS PAE Series Inverter GTI Ben TC Inverter BBI Input from GTI ACLD 40 Load Controller Diversion Load to Pri load to Sec load Diversion Load Figure 2 1 Simplified ACLD System Page 8 2015 Sensata Technologies Installation 2 1 1 Considerations when Installing the ACLD System e The ACLD controller is designed to be connected and powered from the AC output of a battery based inverter that provides a MagNet communications port and has an output of 230 or 240 VAC 50 or 60 Hz Normally this would be the MS PAE Series MS4024PAE or MS4448PAE but can also connect to the MS E Series and MS PE Series inverters e The continuous power rating of the inverter MS PAE Series must be at least 10 larger than the maximum power rating of the renewable energy source Otherwise the inverter may be damaged if required to handle current greater than designed e During an AC utility outage some brands of grid tie inverters are sensitive and disconnect when powered from battery based inverters e Asrequired by the NEC a photovoltaic power system or small wind electric system employing a diversion charge controller of regulating the charging of a battery shall be equipped with a second independent means to prevent overcharging of the battery The MS PAE Series inverters can provide an automatic frequency shift feature that disconnects the grid tie inverter when high voltage is detected on the ba
5. 1 4 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 This causes the critical load sub panel to now be powered from the batteries through the battery based inverter When the battery voltage falls to the low setpoint the relay closes and allows the grid tie inverter to reconnect and begin generating power from the renewable energy If the battery voltage rises again this cycle repeats Disadvantages e Batteries are cycled not regulated does not allow the batteries to be properly charged e Generated power from the renewable energy is wasted while the relay is opened e The DC relay setpoints must be set much higher than required to ensure the DC relay doesn t connect or interfere with normal charging from the battery based inverter and any sell back voltage settings once the utility power returns e No temperature compensated regulation while charging 2 DC diversion driven by DC controlled relays When the battery voltage rises above a maximum setpoint a battery voltage controlled relay is used to switch on a dedicated DC diversion load to consume any excess power When the battery voltage falls to the low setpoint the dedicated div
6. 1 2 What is an AC Coupled system and why do need an ACLD Many homeowners utilize renewable energy i e PV wind etc by installing a high efficiency battery less grid tie inverter also known as an utility interactive inverter to offset their power consumption from the utility grid However these homeowners soon learn that when a utility power outage occurs the grid tie inverter is required to shut down This can cause considerable frustration as the homeowner realizes that the critical loads in the home refrigerator lights water pump etc are no longer powered and all the energy produced by the renewable energy source is being wasted while the utility power is out To overcome some of the disadvantages of a battery less grid tie inverter homeowners add a battery based inverter and batteries to power critical loads during a utility power outage However the generated power from the renewable energy continues to be wasted until the utility power returns 1 This manual will specifically refer to the MS PAE Series to work with the ACLD 40 How ever the ACLD will work with any battery based inverter that provides a MagNet communications port and has an output of 230 or 240 VAC 50 or 60 Hz This means the MS PAE Series MS E Series or MS PE Series inverters will work with the ACLD 40 2015 Sensata Technologies Page 1 Introduction Traditionally when a battery based inverter is used the renewable energy system is connec
7. ACLD 40 AC Load Diversion Controller 4 0kW Owner s Manual 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 This ACLD was proudly assembled and tested in the United States at our facility in Everett Washington At Sensata we are committed to providing you with quality products and services and hope that your experience with us is pleasant and professional Disclaimer of Liability The use of this manual and the conditions or methods of installation operation use and maintenance of the ACLD controller is beyond the control of Sensata Technologies Therefore this company does not assume responsibility and expressly disclaims liability for loss damage or expense whether direct indirect consequential or incidental that may arise out of or be any way connected with such installation operation use or maintenance Due to continuous improvements and product updates the images shown in this manual may not exactly match the unit purchased Restrictions on Use The ACLD may only be used in life support devices and systems with the express written approval of Sensata Technologies Failure of this load diversion controller can reasonably be expected to cause fa
8. Always verify proper wiring prior to turning on the ACLD Use only copper wires with a minimum temperature rating of 75 C 1679F AC wiring must be no less than 10 AWG 5 3 mm gauge copper wire Torque all AC wiring connections to the required values The ACLD must be properly mounted see Section 2 3 Mounting the ACLD in this manual Protection for the AC output wiring against overcurrent is not included in the ACLD and must be provided as part of the system installation Refer to Section 2 8 Wiring the ACLD for more information The AC output neutral conductor is not connected bonded to the ACLD chassis Both the input and output conductors are isolated from the ACLD chassis System grounding if required is the responsibility of the system installer and must comply with local and national electrical codes and standards Page ii 2015 Sensata Technologies Safety Information CONSI GNES DE S CURIT IMPORTANTES CONSERVER CES I NSTRUCTI ONS CE MANUEL CONTIENT DES INSTRUCTIONS IMPORTANTES POUR LE CONTR LEUR 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 syst me Ne pas effectuer toute installation ou service d crit dans le manuel du propri taire moins bien form et capable Mauvaise installation ou entretien peuvent entrainer des risques de choc
9. lectrique d incendie ou autre danger pour la s curit Symboles de s curit Les symboles de s curit suivants ont t plac stout au long de ce manuel pour indiquer des conditions dangereuses et les consignes de s curit importantes Q AVERTISSEMENT Ce symbole indique que le d faut de prendre une action sp cifi e pourraitcauser des dommages physiques l utilisateur N ATTENTION Ce symbole indique que le d faut de prendre une action sp cifi e peut entrainer des dommages l quipement H Info Ce symbole indique une information qui met l accent ou des suppl ments points importants du texte principal Consignes de s curit Tous les travaux lectriques doivent tre effectu s en conformit avec les codes locaux et nationaux lectriques Ce produit est con u pour l installation du compartiment int rieur Il ne doit pas tre expos la pluie la neige l humidit ou des liquides de tout type Utiliser des outils isol s pour r duire le risque de choc lectrique ou courts circuits accidentels Il n y a pas r parable par l utilisateur contenues dans ce produit Cet appareil est fourni avec une protection int grale contre les surcharges Utiliser des m thodes de c blage Classe 1 pour les connexions de c blage sur le terrain aux bornes d un circuit de Classe 2 Cot ou tiquet s quipement doit tre install et utilis conform ment aux instructions figurant dans la liste ou l tique
10. 10 times then off four seconds No Comm condition the ACLD does not detect nor is able to communicate with the inverter network Remedy Disconnect the remote communications cable from the inverter for 5 seconds and then reconnect it see Figure 2 8 If the fault continues then check replace the remote cable Ensure this cable is 4 wire telephone cable see Figure 2 9 This fault will automatically clear once the ACLD starts communicating with the inverter Page 34 2015 Sensata Technologies Appendix A Specifications and Optional Equipment Appendix A Specifications and Optional Equipment A 1 ACLD 40 Load Diversion Controller Specifications Electrical Specifications Input Voltage from inverter amp grid Output Voltage to load Output Waveform to load 240 VAC 10 0 240 VDC Full Rectified Sinewave 50 or 60 Hz 4000 VA 25 C 20 amps AC 25 C Nominal Frequency Input Continuous Rated Power Continuous Rated Current Absolute Maximum Current Input and Output to Loads 30 amps AC Diversion Load Specifications Acceptable Load Type Pure Resistive 2500 4500W 3500 4500W one of the loads must be 110 of renewable source power or greater and must always stay on cannot turn off 208VAC 230VAC or 240VAC Primary Load Rated Power Secondary Load Rated Power Rated Voltage General Features and Capabilities Temperature Compensated Regulation With BTS co
11. 23 Operation The excess current is first 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 configured 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 In this case a secondary load must be connected that can handle the excess current When the primary load is too small or is no longer present e g turned off the ACLD closes an internal relay to connect a secondary load in parallel with the primary load The secondary load must be sized to handle the full power output from the renewable energy source without turning off This secondary load will stay connected until there is no longer any power that needs to be diverted i e PV at night all the current from the energy source is consumed by the critical loads etc Whenever the secondary load disconnects the ACLD begins diverting excess current only to the primary load If the battery voltage begins to rise above the regulated setting the ACLD will reconnect the secondary load again This cycle continues in an effort to ensure the battery voltage is regulated until the utility power returns Once the utility power returns the MS PAE Series inverter reconnects to the utility power and begins to monito
12. ACLD turned on the ACLD will be in the Inactive mode not actively monitoring regulating the battery voltage because the MS PAE Series inverter charger is providing three stage Bulk Absorption and Float battery bank charging is enabled This feature must be disabled for the ACLD to operate correctly To disable the Search Watts feature either connect a load on the inverter s output that is greater than 5 watts or use a remote display ME RC ME ARC or ME RTR to turn the Search Watts setting to OFF If a utility power outage occurs the MS PAE Series inverter comes on and starts powering the critical loads However now that the utility power is no longer connected to the input of the MS PAE Series inverter and the inverter is no longer in the charge mode the ACLD becomes enabled and enters Standby mode In Standby mode the ACLD starts monitoring the battery voltage to determine when to become active and divert power to a diversion load to keep the battery from overcharging During the utility power outage the grid tie inverter after a minimum 5 minute reconnect time reconnects to the AC output waveform of the MS PAE Series inverter and starts inverting all the energy from the renewable energy source just like it did when it was connected to utility power However during a utility power interruption the main panel loads are no longer connected and any excess power that is generated cannot be sold exported to the utility grid Thi
13. Even if a selection other than time is selected for the inverter the ACLD will only use the last Absorption Time setting in the remote Info Contact your battery manufacturer to ensure the best charge settings are used for your type of batteries If the Absorb stage is short or terminated the batteries may not receive a full charge In contrast if the Absorb stage is too long the batteries may be overcharged Either scenario may damage the batteries Info The battery bank size will typically determine the length of the absorption period The larger the battery bank the longer the absorption period is needed to ensure a full charge The owner s manual for the remote display provides guidance on determining the Absorption Time setting based on the amp hr capacity of your battery bank Info If an equalize charge is required this must be performed while utility power is available and connected to the MS PAE Series inverter The ACLD does not allow an equalize charge to be enabled when it is active e EM Float Stage The third stage occurs at the end of the absorb charging time While in the Float stage the charge voltage is reduced to the Float Voltage setting determined by the Battery Type selection In this stage the batteries are kept fully charged and ready if needed by the inverter The Float stage reduces battery gassing minimizes watering requirements for flooded batteries and ensures the batteries are maintained at opt
14. Label includes model serial number information date of manufacture and specifications See the specifications in Appendix A for more information Exhaust Vents ventilation openings that allow heated air to be removed by the internal cooling fan The exhaust air vents are located on the right side and at the rear of the top side ON OFF Power Switch a power switch that turns the ACLD controller on or off C Exhaust Vents on right and top sides ON OFF Power Switch c 8 EE RATINGS D IO PEREA lo009319 82 N amp Z sys HE o T z a 25m ITA Information mt FHR BIC 4 Label on Hi8g0 m 323 ssz2 g F scie sr2 Ec8e B iii A TA HH HEBER SISHIN HEERA Ho UG oQ S E HOTIE bm m m 3 a g EE 15 El w I 3 PN ch Ber a O Figure 1 4 ON OFF Power Switch Info Label and Exhaust Vents The left side of the ACLD controller has an access cover that can be removed Figure 1 5 Wiring Access Cover provides access to the internal AC wiring terminal block and 9 ground busbar This terminal block is used to hardwire all AC wiring connections Remove the two 6 32 screws to access the AC wiring terminal block O o e 6 Wiring Access Cover Figure 1 5 Wiring Access Cover 2015 Sensata Technologies Page 7 Installation 2 0 Installation Read the entire Installation section to determine how best to install the ACLD controller The more thoro
15. ME RC and ME RTR can be used with and configure the ACLD however 2015 Sensata Technologies Page 31 Operation 3 9 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 Status LED Indicator The status indicator refer to Figure 1 3 Item 1 is a green LED Light Emitting Diode that provides information on the operational mode of the ACLD Watch this indicator for at least 10 seconds to determine the controller s operational condition using the information below Normal Operation e Off The ACLD is off Either the power switch on the ACLD controller is off the inverter is not in the Inverter mode there is no AC power to the ACLD or the AC power to the ACLD is incorrect out of tolerance e Blinks on once every second The ACLD is on and operating normally It is either in the Inactive mode grid is present Standby mode monitoring the battery voltage or the Active mode diverting excess current Protection Mode The Status LED is also used to indicate abnormal or fault conditions that cause the ACLD controller to shut down Monitor the Status LED indicator for at least 10 seconds if it blinks and then turns off for four seconds an
16. Voltage setting Active Absorb Current is being diverted to the external load to regulate the battery bank at the Absorb Voltage setting The ACLD will remain in the Absorb stage until the Absorb Time Done setting has been satisfied Active Float Current is being diverted to the external load to regulate the battery bank at the Float Voltage setting The ACLD remains in this stage unless the battery voltage falls to a low voltage which will start another Bulk Charge stage The ACLD also includes an extensive protection circuitry to shut down the controller under certain fault conditions When the ACLD is in a fault condition the controller s green LED blinks 1 10 times depending on the fault and then pauses for four seconds See Section 4 0 to determine the fault condition and find help with troubleshooting 3 8 Monitoring the ACLD Controller with a ME ARC Remote Display The ACLD controller when connected to a ME ARC remote control display Version 4 0 or greater provides access to ACLD meters and the status of the ACLD This gives you the ability to monitor the ACLD controller s operation remotely For specific information on the ACLD menus displayed on the ME ARC see the ME ARC V4 0 Owner s Manual PN 64 0030 Rev C only the ME ARC remote version 4 0 or higher provides displays for the ACLD that indicates ACLD Status Power Diverted ACLD Temperature Target Volts Model and Software Version i Info The
17. energy to work in parallel with the utility to power the loads in the home main panel and critical loads sub panel charge the battery system and feed any surplus renewable energy back into the utility grid MS PAE Series Inverte r AC Load Secondary Critical Loads Grid Tie Inverter Primary E Utility Grid de Renewable Energy i Figure 1 1 ACLD Inactive Utility Power Available Page 2 2015 Sensata Technologies Introduction During a utility power outage see Figure 1 2 When the utility power fails the grid tie inverter disconnects preventing the use of the renewable energy and the MS PAE Series inverter automatically starts powering the critical loads However because the output of the MS PAE Series inverter is connected to the same AC bus as the grid tie inverter and its output waveform is compatible to the utility s waveform the grid tie inverter re synchronizes to the AC output waveform of the MS PAE Series inverter After a minimum 5 minute disconnect period the grid tie inverter reconnects and starts inverting all the energy from the renewable energy source just like it did when it was connected to utility power The grid tie inverter now reconnected using the AC output waveform of the MS PAE Series inverter converts as much of the available renewable energy as possible However during a utility power interruption the main panel loads are no longer connected and the util
18. instructions provided for each component of the system Do not perform any installation or service described in this owner s manual unless properly trained and capable Incorrect installation or service may result in the risk of electric shock fire or other safety hazard Safety Symbols The following safety symbols have been placed throughout this manual to indicate dangerous and important safety instructions P gt gt WARNING This symbol indicates that failure to take a specified action could result in physical harm to the user CAUTION This symbol indicates that failure to take a specified action could result in damage to the equipment Info This symbol indicates information that emphasizes or supplements important points of the main text Safety Precautions All electrical work must be performed in accordance with local and national electrical codes This product is designed for indoor compartment installation It must not be exposed to rain snow moisture or liquids of any type Use insulated tools to reduce the chance of electrical shock or accidental short circuits There are no user serviceable parts contained in this product This unit is provided with integral protection against overloads Use Class 1 wiring methods for field wiring connections to terminals of a Class 2 circuit Listed or labeled equipment shall be installed and used in accordance with any instructions included in the listing or labeling
19. r r r rrrr r 4 1 5 ACLD Features and Benefits na ee aa Rasa ons 6 2 0 THStaHSUDOD nement a a de oeil 8 2 1 Pe i L lli p a en NO UP dab bM CU eat MEE PEE 8 2 2 Locating the AGED ONEONRRS san a ana poussa cause 10 2 3 Mounting the ACLD CODE OINBES nana es ae co open ue 11 2 4 General Wiring Requirements si nnns 13 2 9 Torgus Regue ME ae a ee a EDT 14 2 6 ACLD Terminal Block Connections 15 2 7 Electrical System Wiring Diagrams 15 2 8 Wing Me ACEP u uy u a ea ee r tac 18 2 9 ACED Load ROqUIFSITIGDES ana en VPE SES HII aan uM s puoi cee 19 2 10 Connecting the ACLD to a MS PAE Series Inverter 21 2 11 Using a Remote Control with the ACLD Controller 22 SO OPAGUN aesssinetissddiaibx sain Gem M DN XM DRM d Ru RUD UON pia UN DU 23 3 1 AC OPE AUOT 23 3 2 Three Stage Regulation wessxssasdqauanis bewpad aqux a CAR ER AH n ARCU UTER a c RN RR 25 3 3 Operation Scenarios Utility Connected 26 3 4 Power Flow Scenarios Utility Not Connected 27 5 5 Power Switch Operation catciceannducennsecasaasasanenttenacdGngtanaiessedanareboreceainaaeawne 30 3 6 Inverter Fan ODB eratiOlyu ENSE e E EE 30 3 7 Ope erati g MOES aa ane aa qu
20. 00 LC6025W31 Page 20 2015 Sensata Technologies Installation 2 10 Connecting the ACLD to a MS PAE Series Inverter One end of the ACLD NETWORK cable plugs into the port labeled TO INVERTER orange on the ACLD and the other end plugs into the NETWORK green port on the MS PAE Series inverter see Figure 2 8 Note Do not connect the ACLD NETWORK cable from the inverter into the TO NETWORK green port on the ACLD it will not be damaged but will not operate correctly TO NETWORK port used to connect V additional network B accessories ME ARC Advanced Remote connects to REMOTE blue port on Inverter REMOTE cable MS PAE Series I nverter 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 4 conductor telephone type opposite colors from top to bottom tabs facing toward you same The ACLD NETWORK communications cable is GIF a 6 foot 1 83m 4 conductor twisted pair telephone type with RJ14 m connectors on both ends with a orange colored label on one end and a green NETWORK label on the other end Note This 6 communications cable can b
21. D 2015 Sensata Technologies Page 37 Notes 2015 Sensata Technologies Page 38 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
22. K Md MEN a nan ue 31 3 8 Monitoring the ACLD Controller with a ME ARC Remote Display 31 209 ACLD StartUp a aa i aan ana eka aaea bee ue 32 4 0 Troubleshooting iu uuu u u u u u usus sssanasauwuaianaqamaqupakawanawuwku 33 Appendix A Specifications and Optional Equipment 35 A 1 ACLD 40 Load Diversion Controller Specifications 35 A 2 Regulatory Compliance u u 1 Meist adipis NK KMa paci ar anc ondptad ayaka or Een ea aar 36 A 3 Optional Equipment and JACCeSSOfIG5S essais a XkER V ADR EGnERUS IA CUCXWRI Rea ERR nce 36 Appendix B Warranty and Service 37 B 1 Limited Warranty ARTE 37 B 2 HOW to Receive Repair ServiC EE sd 37 Page iv 2015 Sensata Technologies List of Figures Figure 1 1 ACLD Inactive Utility Power AvallabI ui vociuxd vais bra PUE racisme accep a ct 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 COVEI a eee Date eme due can ee anses ae osmhei cine 7 Figure 2 1 Simplified ACLD System a ae en ee dd ana one a Pow P PERS aies 8 Figure 2 2 Removing Knockouts ea RD a ne RED tetes 10 Figure 2 3 Approved Mounting Positions ae a d RE esd p en 11 Figure 2 4 ACLD Dimensions and Side Reference eene nnn nn 12 Figure 2 5 AC
23. LD Terminal BIOCK u u ae de wb e aD an a ci xU a Sirac Kx Ua Qa 15 PIGUre 2 6 JACEDASVSESTH WING u uuu asua sushakaqa upahuasshianakakaqaliunakuqunsast uaanasqanakuqaspicapaqsuaas 16 Figure 2 7 AC Wiring from Inverter to ACLDD sussundsa ta dire SER CR a SE C orden wenden seinen 17 Figure 2 8 ACLD to Inverter Communications Cable Connection 21 Figure 2 9 ACLD NETWORK Communication Cable averses ssansaceucssensaaasceicescs toscane 21 Figure 3 1 Autormatic 3 Stage Glap aciseeccicacahocrscrnsasstoce eee n rrii aw rinin AA ET 25 Figure 3 2 Utility Connected Surplus Power Fed to the Utility Grid 26 Figure 3 3 Utility Connected Additional Power Provided by the Utility Grid 26 Figure 3 4 Utility not Connected RE Powers Critical Loads 27 Figure 3 5 Utility not Connected Additional Power Provided to Critical Loads 27 Figure 3 6 Utility not Connected Excess Current Charging Battery Bank 28 Figure 3 7 Utility not Connected Diverting some Power to Primary Load 28 Figure 3 8 Utility not Connected Diverting all Power to Primary Load 29 Figure 3 9 Utility not Connected Diverting Power to Secondary Load 29 Figure DO POWEr W C ee da ar vn p een 30 Fig
24. Standby Relay PWM Switch Primary Secondary MagNet Control Load Load Not Powered Not Powered Utility Grid Power Figure 3 6 Utility not Connected Excess Current Charging Battery Bank Since current is now being pushed back thru the AC output of the MS PAE Series inverter and this is not the inverter s normal path to sense incoming current it is not able to regulate the battery voltage To prevent the battery from being over charged the PWM switch inside the ACLD becomes active and starts diverting the excess current to an externally connected primary load see Figure 3 7 Utility Not Connected Diverting some Power to Primary Load ACLD connects primary load to divert some excess current when battery is almost full Renewable Energy DG EH DOLD C DU Battery Bank Battery Almost Full p Note When the battery is almost full the ACLD becomes Active and starts diverting power to the primary load Grid Tie Inverter avy MS PAE Series Inverter av Main Household Loads Critical Loads MagNet Control ACLD Controller Active Relay PWM Switch AN Primary Se
25. abnormal fault condition is occurring Refer to the chart below to determine the fault condition and to Section 4 0 Troubleshooting to help diagnose clear this condition Table 3 1 LED Blinks to Fault Condition Blinks each pause Fault Condition High Current High AC In H Info There are not any fault conditions for 3 and 6 blinks Page 32 2015 Sensata Technologies Troubleshooting 4 0 Troubleshooting This section will help you troubleshoot the ACLD when it has a fault condition The ACLD will indicate a particular abnormal fault condition by how many times the Status LED blinks before pausing To determine the fault condition monitor the Status LED indicator for at least 10 seconds and count the number of blinks that occur before the LED turns off for four seconds After determining the number of blinks refer to the information below to help diagnose clear the condition Blinks On 1 time then off four seconds High Current Fault the current is at least 30 above rated current Remedy Ensure that the load is connected and sized correctly If the load is correct reset the unit The unit is reset by pressing the ON OFF switch on the side of the ACLD controller to the OFF position this removes power to the unit After power is removed press the ON OFF switch to the ON position again to restore power If the fault recurs contact Sensata for service Blinks On 2 times then off four seconds High VAC In Fa
26. ailure 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 If the fault recurs contact Sensata for service Blinks On 7 times then off four seconds Overcurrent Fault the current has reached an extremely high level about twice the rated current Remedy This fault could be the result of too big of a load Ensure the loads are sized and connected correctly 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 See Section 2 9 2 on load sizing criteria Blinks On 8 times then off four seconds Output Short Fault a shorted output to loads has been detected Remedy Check to ensure that the loads are sized and connected correctly See Section 2 9 2 on load sizing criteria Refer to Figure 3 11 to check the load resistance Blinks On 9 times then off four seconds Overtemp Fault the internal temperature of the ACLD controller has risen above 90 C Remedy This fault can be caused by loads too great for the controller to operate F4 continuously see Section 2 9 2 on load sizing criteria or by the lack of ventilation to the controller check for objects in front of the fan grill Once the temperature falls below 70 C the fault automatically clears and the ACLD will resume operation Blinks On
27. condary Load Load Powered Not Powered Utility Grid Power Figure 3 7 Utility not Connected Diverting some Power to Primary Load Page 28 O 2015 Sensata Technologies 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 Energy Inverter mine rhe C DC CQ DG ww FERE 6 js js wv Battery MS PAE Series Bank Inverter PAPE aaas j js Ss Battery B y Main Household Note The ACLD is still Active and Loads when the battery is full all the power is diverted to the primary load MagNet Control ACLD Controller Active Relay PWM Switch D Primary Secondary m Load Load Powered Not Powered Utility Grid Power Figure 3 8 Utility not Connected Diverting all Power to Primary Load If the primary load is not large enough to consume all the excess power
28. ctions of an on off switch and is a 20 amp circuit breaker that provides overload protection for wiring inside the load controller The ACLD can be turned ON I or OFF O by pressing the power switch ON 1 The controller will be powered if 240 volt AC from the utility ON grid or MS PAE Series inverter is present at the INV OUT terminals The load controller passes this incoming 240 volt power to the OFF grid tie inverter through the Electrical Panel terminals on the load controller The 240 volt power is used as the synchronizing voltage and frequency signal which the grid tie inverter requires to power up OFF QO The controller is not powered but is allowed to pass the Figure 3 10 incoming power through Power Switch CAUTION When the power switch is in the off O position the ACLD will not be able to regulate the battery voltage Info The power switch is labeled with universal I and O symbols The I line symbol represents power on and the O circle symbol represents power off These symbols come from the binary system means on and O means off Info If the automatic protection circuit has turned the controller off the power switch will need to be pressed OFF O then back ON I to clear the fault and restart the load controller Info The switch operates as a latched mechanism and the ON OFF power switch function is independent of the overload protection trip function pee De
29. d should be at least 4400 CAUTION To prevent the battery from being overcharged and damaged it is critical N that one of the diversion loads connected to the ACLD must always be available must not be thermostat controlled or be able to be turned off and be correctly sized to handle the full power produced by the renewable energy source wind hydro etc If only one load is wired to the ACLD it must be sized correctly and always be on and available it cannot be allowed to turn off However if there is both a primary and secondary load wired to the ACLD then the primary load does not need to stay on nor is it required to be sized to handle the full output current of the renewable energy source However if the primary load is allowed to turn off i e water heater with thermostat control or not large enough to handle the full output current then the secondary load is used as a back up to the primary load and must always be on and available if needed and correctly sized to handle the full power produced by the renewable energy source wind hydro etc Note If the primary load is not sized large enough to consume the excess power the ACLD will activate an internal relay to connect the secondary load in parallel with the primary load Once the secondary load connects the benefit of the primary load will not be utilized because the current to the primary load will be decreased For example if the primary load is a small water heate
30. e extended up to a length of 200 feet without data degradation Figure 2 9 ACLD NETWORK Communication Cable 2015 Sensata Technologies Page 21 Installation 2 11 Using a Remote Control with the ACLD Controller A remote control display ME ARC ME RC1 or ME RTR is used to configure the MS PAE Series inverter to ensure the ACLD controller operates correctly During the Standby and Active modes the ACLD controller is in charge of monitoring and regulating the battery voltage and determining the absorption charge time The following settings in the remote display should be adjusted to operate with the ACLD Set the Battery Type to Custom this setting is used to determine the battery voltage regulation level and also enables the frequency shift feature Once the battery type is set to Custom the battery voltage settings i e bulk and float must be set to the correct regulation values for your battery type increase it s output frequency when high voltage is detected on the battery This frequency shift is enough to cause the utility interactive inverter to disconnect and stop charging the battery bank 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 The frequency shift feature is enabled whe
31. e going to use cable clamps or conduit using the optional MPX CB conduit box and the different wiring required See Section 2 4 3 for wire routing requirements to from the ACLD controller Figure 2 2 Removing Knockouts Page 10 2015 Sensata Technologies Installation 2 3 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 e above or under a horizontal surface shelf or table e ona vertical surface wall with the intake cooling fan to the right e ona vertical surface wall with the intake cooling fan toward the bottom and an optional MPX CB conduit box installed below the controller Info The four mounting holes on the ACLD have a diameter of 0 280 7 11 mm good for 1 4 bolts screws see Figure 2 4 for hole locations Info The MPX CB prevents material from falling out the bottom in the event of an internal fire and also allows sufficient ventilation to prevent the ACLD controller from overheating under normal operating conditions Info Sensata provides a backplate that can be used to mount the ACLD and if required the MPX CB This backplate part number is BP S Back Plate Single ee After determining the mounting position refer to the physical dimensions as show
32. e ACLD s internal electronic overcurrent protection circuitry CAUTION The ACLD internal wires are rated for 30 amps the pass thru current must N be no greater than 30 amps or damage to the ACLD will occur CAUTION The wiring must be no less than 10 AWG 5 3 mm gauge copper wire N and be approved for the application i e residential wiring 2 5 Torque Requirements Follow the specific torque recommendations below to ensure your fasteners are tightened sufficiently To ensure your connections are correct you should use an accurate quality torque wrench It is highly recommended to go back over all fasteners and re torque after five days and every six months thereafter Table 2 1 Torque Values for Ground Busbar Note The ground busbar has different torque values for the small and large screws Busbar Screw Size Torque Values 10 32 Small Screw 5 16 24 Large Screw 14 to 10 AWG 2 1 to 5 3 mm2 15 in Ibs 1 7 N m 35 in Ibs 4 0 N m 8 AWG 8 4 mm 20 in Ibs 2 3 N m 40 in Ibs 4 5 N m eee 25 in Ibs 2 8 N m 45 in Ibs 5 1 N m 4 AWG 21 1 mm 45 in Ibs 5 1 N m 3 to 1 0 AWG l EE E Table 2 2 Torque Values for the AC Terminal Blocks MireSize Slotted M3 5 Screw Torque Values 14 to 6 AWG 16 in Ibs maximum 2 1 to 13 4 mm 1 8 N m maximum Page 14 2015 Sensata Technologies Installation 2 6 ACLD Terminal Block Connections The ACLD controller has a ten po
33. e 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 Route wires from the inverter s AC output HOT 1 OUT HOT 2 OUT and NEUTRAL thru the unused strain relief clamp on the inverter and into the ACLD using an appropriate knockout 2 Connect the HOT 1 OUT black wire from the inverter s INV HOT 1 OUT terminal to the INV OUT HOT 1 terminal on the ACLD 3 Connect the HOT 2 OUT red wire from the inverter s INV HOT 2 OUT terminal to the INV OUT HOT 2 terminal on the ACLD 4 Connect a NEUTRAL white from one of the inverter s AC NEUTRAL terminals to one of the NEUTRAL terminals on the ACLD Wiring from the ACLD to the Critical Loads Sub panel thru circuit protection 1 On the ACLD terminal block connect a black wire to the ELECTRIC PANEL L1 terminal a red wire to ELECTRIC PANEL L2 terminal and a white wire to the unused NEUTRAL terminal 2 Connect a wire green or bare copper to the GROUND busbar on the ACLD 3 Route the ELECTRIC PANEL L1 and ELECTRIC PANEL L2 NEUTRAL and GROUND wires through an appropriate knockout on the ACLD to an enclosure with a dual pole 30A branch rated circuit breaker using minimum 10 AWG 5 3 mm wire 4 Connect the ELECTRIC PANEL L1 and ELECTRIC PANEL L2 wires t
34. e diversion load is too large it will draw more current than the rating of the controller causing damage or causing the controller s protection circuits to open the load e Multiple controllers are usually needed even for medium sized renewable energy systems i e a 4KW 48VDC system requires at least a 70 amp controller e The regulation setpoint must be set much higher than required to ensure the diversion load is not always in regulation and that it doesn t interfere with normal charging from the battery based inverter or any sell back voltage settings once the utility power returns e Since excess power is regulated on the DC side the battery based inverter is required to be always on re converting the renewable energy from AC back to DC where it is diverted this extra conversion step creates energy loss and there is an unnecessary use of the inverter Page 4 2015 Sensata Technologies Introduction 4 Frequency disturbance shift from the battery based inverter When the battery voltage rises above a maximum setpoint a battery based inverter changes its output frequency to cause the grid tie inverter to limit the energy from the renewable energy source to the battery Disadvantages e Generated power from the renewable energy is limited wasted during the frequency shift e Batteries are cycled not regulated does not allow the batteries to get properly charged e The frequency shift setpoint must be set higher than requ
35. el tel P 3 6 Inverter Fan Operation The ACLD contains a cooling fan that is automatically controlled The fan speed increases or decreases based on the output power and the internal temperature of the controller The controller s fan operates under the following conditions e Fan comes on momentarily when the ACLD is first turned on e Fan comes on when the controller s operating power and or internal temperature creates a proportional temperature that is greater than 40 C 104 F and stops if there is no load and the temperature drops to 35 C 95 F or lower Note The ACLD s fan will not come on based on temperature sensed by the optional Battery Temperature Sensor Page 30 2015 Sensata Technologies Operation 3 7 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 Standby In the Standby mode the ACLD no longer senses utility power and begins monitoring the battery voltage to determine when to become active and begin diverting power Once Standby mode has been initiated the ACLD then determines the regulation stage If the battery voltage is low lt 12 8 VDC 12v inverter
36. ergy 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 The utility power connects to the input of the MS PAE Series inverter charger This causes an automatic AC transfer relay inside the inverter to close passing the current from the incoming utility power through the MS PAE Series inverter Some of the current passing thru the MS PAE Series inverter is used by a powerful internal battery charger to keep the battery bank charged in case of a power failure Info The ACLD controller is designed to be connected and powered from the AC output H of a battery based inverter that provides a MagNet communications port and has an output of 230 or 240 VAC 50 or 60 Hz Typically the MS PAE Series MS4024PAE or MS4448PAE is used but the MS E Series and MS PE Series inverters can also be used for applications that require 230VAC 50Hz inverters The current that passes thru the MS PAE Series inverter connects and powers the ACLD and then passes through the ACLD to the grid tie inverter Once power is connected to the ACLD the ON OFF power switch Figure 1 4 Item 8 on the ACLD controller must be turned on to begin operating The controller s green LED blinks slowly once a second when the ACLD is on With utility power connected and the
37. ersion load turns off If the battery voltage rises again this cycle repeats Disadvantages e Batteries are cycled not regulated does not allow the batteries to be properly charged e Difficult to source and size DC diversion loads to absorb the full output of the renewable energy source e The regulation setpoint must be set much higher than required to ensure the diversion load is not always in regulation and that it doesn t interfere with normal charging from the battery based inverter or any sell back voltage settings once the utility power returns e Since excess power is regulated on the DC side the battery based inverter is required to be always on re converting the renewable energy from AC back to DC where it is diverted an extra conversion step creates energy loss and there is an unnecessary use of the inverter e No temperature compensated regulation while charging 3 DC Diversion Controller off the battery When the battery voltage rises above a voltage regulation setpoint the DC Diversion Controller sends excess current to a dedicated DC 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 Disadvantages e Difficult to source and size DC diversion loads correctly If the load is too small it cannot divert enough power from the source wind hydro etc and the battery could be overcharged If th
38. ess of temperature See the owner s manual for your MS PAE Series inverter to determine the amount of change to the voltage level based on temperature Info Once Standby mode has been initiated the ACLD determines the initial regulation H stage If the battery voltage is greater than 25 6 volts for a 24 volt inverter system gt 51 2 VDC for a 48 volt system the ACLD will skip the Bulk Absorb stages and go directly to the Float stage Standby Float If the battery voltage is 25 6 volts or less for a 24 volt inverter system or lt 51 2 VDC for a 48 volt system the ACLD goes to the Bulk stage Standby Bulk Info The ACLD controller monitors the battery voltage to help determine when to start H regulating the current from the renewable sources connected to the AC side of the system to the battery Even though the ACLD monitors battery voltage if there is an external charging source i e PV or hydro connected directly to the battery a voltage regulator controller different and independent of the ACLD must be connected on the DC side to prevent the batteries from being overcharged Info The internal relay will close and connect the secondary load if the primary load H is open or less than 4kW Once this relay has closed it will stay closed until there is no longer any power that needs to be diverted i e PV at night all the current from the energy source is consumed by the critical loads etc or determines that there is to muc
39. h current being drawn Page 24 2015 Sensata Technologies Operation 3 2 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 When active the ACLD uses the following three stage process to determine when to divert the excess current to regulate the battery voltage Bulk Stage This is the initial stage While in the Bulk stage the ACLD allows as much current as available to charge the battery The ACLD remains in this stage until the absorb voltage is achieved The absorb voltage is determined by the Battery Type settings in the MS PAE Series inverter Absorb Stage This is the second stage and begins after the absorb voltage has been reached The Absorb stage provides the batteries with a constant voltage and will divert current to the diversion load in order to maintain the Absorb Voltage setting The ACLD stays in the Absorb stage until the batteries have been maintained at the absorb voltage level for the entire absorption period as determined by the Absorption Time setting then switches to the Float stage Info The remote control provides several ways to determine the inverter s absorption period i e time amps or SOC
40. ical Sqitch Battery MS PAE Series Loads Bank Inverter Relay Battery Full Primary Secondary av MagNet Control Load Load Not powered Not powered Main Cio ST Utility Household he Grid Power Note When the MS PAE Series inverter Loads is connected to the utility and charging the battery the ALCD is Inactive Figure 3 2 Utility Connected Surplus Power Fed to the Utility Grid During occasions when the renewable energy is less than the power required by the loads in the home i e PV system on a cloudy day the additional power is provided by the utility to continue powering the household and critical loads see Figure 3 3 Utility Connected Additional Power Provided by the Utility Grid Renewable Energy less than Household and Critical Loads Renewable Grid Tie Energy Inverter ACLD Controller m imm Inactive dr D k D D p aay au OCL D JC D D DA DA Ad Dg CDD Relay
41. ilure of that life support device or system or to affect the safety or effectiveness of that device or system If the ACLD fails it is reasonable to assume the health of the user or other persons may be endangered Copyright Notice Copyright 2015 by Sensata Technologies All rights reserved Permission to copy distribute and or modify this document is prohibited without express written permission from Sensata Technologies Document I nformation Description ACLD 40 Owner s Manual Part Number and Revision 64 0062 Rev A Date Published February 2015 This manual is printed without color for cost savings However this entire manual is available for download with many of the figures available in color under the Document Library tab at www Magnum Dimensions com Contact Information For Magnum Dimensions Products Sensata Technologies 2211 West Casino Rd Everett WA 98204 Phone 425 353 8833 Fax 425 353 8390 Web www Magnum Dimensions com Record the ACLD s serial number in case you need to provide this information in the future x Mode O Serial Number 2015 Sensata Technologies Page i 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
42. imited warranty period Sensata Technologies will repair or replace at Sensata s option any defective parts or any parts that will not properly operate for their intended use with factory new or rebuilt replacement items if such repair replacement is needed because of product malfunction or failure during normal usage The limited warranty does not cover structural or non operative parts or any defects in appearance be they cosmetic or decorative Sensata Technologies limit of liability under the limited warranty shall be the actual cash value of the product at the time the original purchaser returns the product for repair determined by the price paid by the original purchaser Sensata shall not be liable for any other losses or damages Upon request from Sensata Technologies the original purchaser must prove the product s original date of purchase by presenting a dated bill of sale or itemized receipt The original purchaser shall return the product prepaid to Sensata Technologies in Everett WA or to one of Sensata s Authorized Service Centers ASC After the completion of service under this limited warranty the product will be returned prepaid to the original purchaser via non expedited surface freight within the contiguous United States and Canada this excludes Alaska and Hawaii If Sensata repairs or replaces a product its warranty continues for the remaining portion of the original warranty period or 90 days from the date of the retu
43. imum capacity These settings are in the MS PAE Series inverter and communicated to the ACLD They have a factory default value but are changeable The default values are listed in the owner s manual for your MS PAE Series inverter and are adequate for most installations However if you determine that some of the default values are not appropriate for your particular system a remote control can be used to change these settings in the MS PAE Series inverter Bulk Stage Absorb Stage Float Stage 1 Absorb volts Absorb Float volts Time Increased Constant Reduced Voltage Voltage Voltage Figure 3 1 Automatic 3 Stage Graph 2015 Sensata Technologies Page 25 Operation 3 3 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 Some of this power is used by the battery charger inside of the MS PAE Series inverter to keep the battery bank charged in case of a power failure If there is any surplus renewable energy after satisfying the loads in the home it is fed back into the utility grid see Figure 3 2 Utility Connected Surplus Power Fed to the Utility Grid Renewable Energy greater than Household and Critical Loads Renewable Grid Tie Inverter ACLD Controller Inactive PWM l A Crit
44. ired to ensure it doesn t interfere with normal charging from the battery based inverter or any sell back voltage settings once the utility power returns e No temperature compensated regulation while charging Note May not occur if networked to the grid tie inverter 5 AC diversion driven by DC controlled relays A battery voltage controlled relay is used to switch on a dedicated AC diversion load i e space heater air conditioner etc to consume any excess power when the battery voltage rises above a maximum setpoint When the battery voltage falls to the low setpoint the dedicated diversion load turns off If the battery voltage rises again this cycle repeats Disadvantages e Batteries are cycled not regulated does not allow the batteries to be properly charged e AC diversion loads must be sized to absorb the full output of the renewable energy source and configured to always be on no temperature or thermostat turn off control e AC diversion loads when activated can cause enough AC line drop disturbance to disconnect the grid tie inverter wasting generated energy e No temperature compensated regulation while charging 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 se
45. issing or damaged contact Sensata If at all possible keep your shipping box to help protect your ACLD controller from damage if it ever needs to be returned for service Important Save your proof of purchase as a record of your ownership it will be required if the ACLD should require in warranty repair Record the unit s model and serial number in the front of this manual in case you need to provide this information in the future It will probably be much easier to record this information now rather than trying to gather it after the unit has been installed 2 1 3 Required Tools and Materials Hardware Materials e Conduit or strain reliefs and appropriate fittings Mounting bolts and lock washers e Electrical tape e Wire ties Tools e Miscellaneous screwdrivers e Pliers e Wire strippers e Drill and drill bits e Pencil or marker e Multimeter e Level e 1 2 wrench 2015 Sensata Technologies Page 9 Installation 2 2 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 Failure due to any of the above conditions is not covered under warranty putting silicone dielectric grea
46. itor the ACLD This remote provides displays for the ACLD that indicates ACLD Status Power Diverted ACLD Temperature Target Volts Model and Software Version Info When utility power is connected and the ACLD is in the Inactive mode the MS H PAE Series inverter is in charge of maintaining the battery bank using the Absorb and Float voltage settings in your remote During the Standby and Active operating modes of the ACLD when utility power is lost the same absorb and float voltage settings in your remote are used to regulate the current to the battery Therefore these two settings absorb and float voltage settings should already be adjusted correctly and do not need to be changed when installing the ACLD Info If the ACLD is used without a remote the Battery Type will be defaulted to H Flooded and the Absorb Time will be set at 2 0 hours Also a load greater than 5 watts must always be connected to the inverter s output to ensure the Search mode is defeated i e search turned off The ME RC and ME RTR can be used with and configure the ACLD however only the ME ARC remote version 4 0 or higher provides displays for the ACLD that indicates ACLD Status Power Diverted ACLD Temperature Target Volts Model and Software Version Page 22 O 2015 Sensata Technologies Operation 3 0 Operation 3 1 ACLD Operation Normally when utility power is available the grid tie inverter in the system converts the renewable en
47. ity grid is not available to export any excess power that is generated This means there may be more power on the AC bus than the critical loads can consume causing current to be pushed back thru the AC output of the MS PAE Series inverter into the battery bank Since this is not the normal path for the MS PAE Series inverter to sense incoming current it is not able to control the battery voltage or regulate the current which requires the inverter to be rated to handle the full power output of the renewable energy source If the renewable energy provides more current that the critical loads can use there is the possibility that the battery voltage will rise and cause damage to the battery If the battery voltage is allowed to rise high enough a High Battery Voltage fault on the 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 MS PAE Series Inverter Utility ACLD 40 Controller AC Load Secondary Critical Loads AC Load Primary d Grid Tie Inverter Renewable Energy RE E gt Inverter power when RE not ses available Figure 1 2 ACLD Active Utility Power NOT Available 2015 Sensata Technologies Page 3 Introduction
48. lations The NEC or CEC lists the requirement for wire sizes overcurrent protection and installation methods and requirements WARNING Because the ACLD is wired with an inverter charger there is power from Ji multiple sources inverter generator utility batteries solar arrays etc which make the wiring more hazardous and challenging Ensure they are all de energized i e breakers opened fuses removed before proceeding to prevent accidental shock 2 4 1 Protecting Wire Conduit Box The AC wires to and from the load controller must be protected as required by code This can be done by using jacketed wires or by feeding the wires through conduit A conduit box MPX CB is available that allows the AC conduit to be connected to the ACLD controller 2 4 2 Wiring Requirements e All conductors that are at risk for physical damage must be protected by conduit tape or placed in a raceway e Always check for existing electrical plumbing or other areas of potential damage prior to making cuts in structural surfaces or walls e AC overcurrent protection must be provided as part of the installation and be properly sized e Use only copper wires with a minimum temperature rating of 75 C 1679F e Always use properly rated circuit breakers If using an electrical sub panel circuit breakers can be moved from the main electrical panel to the sub panel only if the breakers are also listed to be installed in the sub panel e Wiring m
49. le 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 Each connection on the terminal block is rated to accept one 14 to 6 AWG 2 1 to 13 4 mm CU stranded wire or two 12 AWG 3 3 mm CU stranded wires Each connection uses a M3 5 slotted head screw and the maximum tightening torque is 16 in Ibs 1 8 N m Info Both of the ACLD s NEUTRAL terminals are electrically connected to each other and either connection can be used to connect the inverter and electrical panel The ground busbar has two 14 to 1 0 AWG 2 1 to 53 6 mm and three 14 to 6 AWG 2 1 to 13 4 mm compression terminals with slotted head screws See Table 2 1 for torque requirements I NPUT GTI OUTPUT OUTPUT PRI SEC L o Ke Un GS a6 TD C 35 o O c D From Sub Panel Grid Load LEG 1 From Sub Panel Grid Tie Inverter LEG 1 out Tie Inverter LEG 2 out From MS PAE Series inverter HOT 2 out From MS PAE Series inverter HOT 1 out Load LEG 2 Load LEG 1 To Secondary Load LEG 2 To Secondary To Primary 4 Common Neutrals from inverters N O SA Figure 2 5 ACLD Terminal B
50. le the maximum load current The wiring must be protected from short circuits and overloads by an overcurrent protection device This overcurrent protection device must have a means to disconnect the circuits e g circuit breaker or a fuse disconnect be properly sized and branch circuit rated for the wire it is protecting As shown in Figure 2 5 the ACLD provides two input circuits the Battery Based Inverter BBI and Grid Tie Inverter GTI input circuits As part of the installation overcurrent protection rated to handle a maximum 30 amps must be provided from the source to these two input circuits A dual pole 30 amp 240 volt branch rated circuit breaker to protect both L1 and L2 circuits for each input circuit is required Referring to Figure 2 6 the BBI input to the ACLD terminals 1 and 2 is protected from a 30A breaker from the main utility panel and the GTI input to the ACLD terminals 5 and 6 is protected using the 30A breaker in the MMP Note If the MMP enclosure is not used an external panel with a 30A breaker must be provided to protect the GTI input from the Grid Tie Inverter The ACLD also provides a primary output circuit terminals 7 and 8 and secondary output circuit terminals 9 and 10 that are connected to the diversion loads An external overcurrent protection device is not required for these two output circuits as the diversion loads are the only connections to these two circuits and these circuits are protected by th
51. lock 2 7 Electrical System Wiring Diagrams A diagram of the wiring for the ACLD controller is shown in Figure 2 6 and is provided to assist you or your system installer Due to the variety of applications and differences in local and national electrical codes this wiring diagram should be used as a general guideline only It is not intended to override or restrict any national or local electrical codes and this diagram should not be the determining factor as to whether the installation is compliant that is the responsibility of the electrician and the onsite inspector 2015 Sensata Technologies Page 15 Installation Ae11 21823 0A010 d LLL Li mm SSS Rss en m EE mm umm um m m n m 1939 Ann euomooeJrq g Jo9oMOd pius Aynn DM uum mmm um m m ER SE c SS sense mm nr mm umm m m m ner V ZHO9 OVAOVC OCT
52. n in Figure 2 4 or use the base of the ACLD as a template to mark your mounting screw locations After marking the mounting screw locations mount the controller with appropriate mounting hardware SHELF OR TABLE MOUNTED Fan facing away from wall WALL MOUNTED Fan facing down and MPX CB installed When the unit is mounted in this position either the MPX CB MPX conduit box or MMP Series ios cse must be attached elow WALL MOUNTED Fan to the right Figure 2 3 Approved Mounting Positions 2015 Sensata Technologies Page 11 Installation apis 74ub1y 92U919J9YH 9PIS pue suoisueuiig G1DV p z e4nbi4 P808 __ p S H T so2eld p LS TZ 0 08c UD 9 p ig CT SjU9A jsneux3 UD 9 gz ut TT p WD p z We cl px px O sinopouy WOT ZT lt O enq We 9 E ZA O O uA 8 ih em apis peg 2015 Sensata Technologies Page 12 Installation 2 4 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 qualified 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 instal
53. n the Battery Type is set to Custom using an optional remote that allows Battery Type to be set to Custom This feature automatically activates when the battery voltage increases 2 volts 24v units or 4 volts for 48v units above the Absorb Voltage setting When activated the output frequency of the MS PAE Series inverter increases to 60 6Hz causing the utility interactive inverter to disconnect When the battery voltage falls 2 volts 24v units or 4 volts for 48v units below the Absorb Voltage setting the frequency returns to 60 0Hz allowing the utility interactive inverter to reconnect Info The frequency shift feature causes the MS PAE Series inverter to automatically e Setthe Absorb Time this setting is used to determine the time that the ACLD will regulate the battery at the absorption voltage e Defeat the Search Watts feature when the MS PAE Series inverter is first turned on its automatic search feature is enabled This feature must be disabled for the ACLD to operate correctly To disable the Search Watts feature turn the Search Watts setting to OFF e Set the Final Charge Stage to Float change the final charge stage setting if available on your remote control from Multi to Float This ensures that the battery is ready and maintained if a power outage occurs and the RE source is not available i e night time Note The ACLD requires a ME ARC remote display version 4 0 or higher to mon
54. nnected to inverter Internal Cooling Uses ball bearing fan for long life Integrated Electronic Protection Overcurrent and overtemperature ETL listed to UL cUL 1741 2nd edition CSA C22 2 No 107 1 01 Three years Five years when purchased with and installed on a MMP or MP enclosure system 20 C to 60 C 4 F to 140 F 40 C to 70 C 40 F to 158 F 0 to 95 RH non condensing Safety Listings Warranty Operating Temperature Non operating Temperature Operating Humidity Physical Specifications Enclosure Type Enclosure Environmental Rating Type 1 indoor only Unit Dimensions width x height x depth 13 x 15 75 x Z 33 C x 54 9 cm x 178 em Shipping Dimensions w x h x d 16 x 17 x 10 5 40 6 cm x 43 2 cm x 26 7 cm Top of shelf or table or specifically mounted on a vertical surface wall Unit 20 Ib 9 1 kg Shipping 23 Ib 10 5 kg 15 000 ft 4570 m Mounting Weight Max Operating Altitude Unless otherwise noted specifications 77 F 25 C subject to change without notice 2015 Sensata Technologies Page 35 Appendix A Specifications and Optional Equipment A 2 Regulatory Compliance The ACLD controller is designated as a diversion controller It is used to divert excess power from a renewable energy source when connected in an 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 k
55. nown as utility interactive device and does not have the capability to export or sell power back into the utility grid The ACLD controller is intended to be used for residential or commercial applications It has been tested and listed to UL 1741 2nd Edition Inverters Converters and Controllers for Use in Independent Power Systems for use in the US and is also certified to CSA C22 2 No 107 1 01 General Use Power Supplies for use in Canada It has been tested and certified to these product safety standards by Intertek Testing Services known as ETL which is a Nationally Recognized Testing Laboratory NRTL NRTL s are qualified organizations that meet Occupational Safety and Health Administration OSHA regulations to perform independent safety testing and product certification A 3 Optional Equipment and Accessories The following components are available for use with the ACLD 40 Some of these items are required depends upon the intended use of the inverter MMP Series Enclosures The MMP175 30D MMP175 60S MMP250 30D and MMP250 60S enclosures are for single inverter applications The MMP Series enclosures have been specifically designed to combine all of the major components required for a renewable energy system inverter battery disconnect AC overcurrent protection grounding connections and a full system inverter bypass switch as a convenient way to isolate the inverter for battery maintenance into a single easy to install
56. nt to the dedicated diversion load Advantages e Batteries are properly charged regulated true three stage charging to batteries during power outage e Easier to source and size AC diversion loads to absorb the full output of the renewable energy source e Primary AC diversion loads can be configured for temperature thermostat turn off primary loads are not required to always be on e AC diversion loads are isolated from the grid tie inverter s output to provide a smooth turn on transition prevents the inverter from disconnecting due to AC line drop disturbance e ACLD 40 communicates with the MS PAE Series inverter this provides o No confusion or interference trying to coordinate the inverter s and controller s setpoints once the utility power returns controller uses same charge setpoints as the MS PAE Series inverter for regulation o Temperature compensated regulation while charging uses temperature sensor readings from the MS PAE Series inverter o Information on diverted power and the controller s status can be displayed using a remote control o Knows when grid power returns ensures the renewable energy is not being diverted and is available to be fed back to the utility grid e Does not require multiple current sensors and devices all current flow is monitored at the controller to determine when to divert excess current e No AC to DC energy conversion loss when trying to regulate battery voltage excess powe
57. o the line side of the dual pole 30A circuit breaker one wire for each pole See Section 2 4 4 for breaker information Info Figures 2 6 and 2 7 show the ACLD wired through a MMP 30D Series enclosure H The MMP 30D Series enclosures provide the required branch rated 30 amp circuit breaker These enclosures also provide a full system Inverter Bypass Switch This simple item provides a convenient way to isolate the ACLD and inverter from the AC loads without any re wiring which could save you hours of downtime if you ever need to service your load controller or inverter 5 From the load side of the dual pole 30A circuit breaker connect the ELECTRIC PANEL L1 and ELECTRIC PANEL L2 wires and route along with the NEUTRAL and GROUND wire on the ACLD to the AC electrical sub panel Wiring to the Diversion Load 1 On the ACLD terminal block connect a black wire to the PRIMARY LOAD L1 terminal and a red wire to PRIMARY LOAD L2 terminal 2 Connect a wire green or bare copper to the GROUND busbar on the ACLD 3 Route the wires PRIMARY LOAD L1 PRIMARY LOAD L2 and GROUND through an appropriate knockout on the ACLD to a diversion load See Section 2 4 4 for diversion load information Info If connecting a secondary diversion load use the same three steps listed above H except connect a black wire to the SECONDARY LOAD L1 terminal a red wire to SECONDARY LOAD L2 terminal and connect an additional GROUND wire Wiring In
58. on the MagNet network either MagWeb provides live internet monitoring of the inverter battery monitor and automatic generator start module Using your always on Internet connection either MagWeb makes live and historical conditions available to you MPX CB Conduit Boxes The MPX CB Conduit Box is provided for installations where the electrical code requires the wiring to the ACLD to be enclosed and protected by conduit The top side is designed to fit MS PAE Series inverters It has conduit knockouts on each side and on the bottom Page 36 2015 Sensata Technologies Appendix B Warranty amp Service Appendix B Warranty and Service B 1 Limited Warranty Sensata Technologies warrants the ACLD 40 to be free from defects in material and workmanship that may result in product failure during normal usage according to the following terms and conditions 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 The limited warranty extends to the original purchaser of the product and is not assignable or transferable to any subsequent purchaser During the l
59. or turns off the ACLD will activate an internal relay to connect a secondary load in parallel with the primary load The secondary load must always be on and available and sized to handle the full current capacity of the renewable energy source to prevent the battery bank from being over charged see Figure 3 9 Utility Not Connected Diverting Power to Secondary Load Primary load turns off ACLD connects secondary load to prevent battery overcharge Renewable Grid Tie Inverter D Bank Inverter V Main Note The ACLD is still Active and Household connects the secondary load because the primary load has Loads turned off or is not able to divert the current away from the battery is AV Battery MS PAE Series ACLD Controller Active Relay Primary Secondary MagNet Control Load Load Turned Off Powered and always on Utility Grid Power Figure 3 9 Utility not Connected Diverting Power to Secondary Load 2015 Sensata Technologies Page 29 Operation 3 5 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 fun
60. ors or electric heating elements rated for 240 volts RMS should be used CAUTION Ensure the diversion load is sized correctly If the diversion load is sized too N low or too high the ACLD could fault and disconnect possibly resulting in damage to the system battery or other system components 2 9 1 Selecting and Sizing the Diversion Load To size the diversion load you should first consider the MS PAE Series inverter that will be used with the ACLD controller The power output of the renewable energy source must be sized 10 lower than the continuous power rating of the chosen inverter This is to ensure the inverter will not be damaged when handling the maximum current from the renewable energy source The load must have a total power rating at least 10 greater than the renewable energy source s maximum output to ensure all the excess current can be diverted from the batteries to prevent overcharging Also each load primary or secondary must be no less than 2500 watts or greater than 5000 watts to prevent the controller s overload protection from activating if this happens the diversion load would disconnect allowing all the excess current to go into the battery causing an overcharge condition Note If using the MS4024PAE the renewable energy source must be no greater than 3600 watts and the load should be at least 4000 watts For the MS4448PAE the renewable energy source must be no greater than 4000 watts and the diversion loa
61. pre wired enclosure MP Series Enclosures The MPSL MPSH MPDH enclosures have been specifically designed to easily work with multiple stacked inverters The MP enclosures feature convenient front mounted AC and DC connections and easy front panel operation Depending on the MP enclosure you can connect from 2 to 4 inverters together using the MPX Series extensions to handle your power capacity needs Advanced Remote Control The ME ARC remote control panel uses an LCD screen and at a glance LED s to provide operating information and allow advanced features if available to be configured This LCD remote control also provides advanced monitoring troubleshooting and includes a FAVS button to quickly access your favorite features Battery Monitor The Battery Monitor Kit ME BMK is a single battery bank amp hour meter that monitors the condition of the battery provides information to let you know how much energy you have available and lets you plan your electrical usage to ensure the battery is not being over discharged The ME BMK NS version does not include a DC shunt You must order the ME BMK to receive a 500A 50mv DC shunt Note The DC shunt is included with MMP and MP Series enclosures Order the ME BMK NS version when installed with the MMP or MP enclosures MagWeb The MagWeb Wireless ME MW W or MagWeb Ethernet ME MW E are powerful and cost effective tools for remotely monitoring the inverter and accessories Installed
62. r and the renewable energy is greater than the small water heater can handle the ACLD will connect the secondary load Once the secondary has connected the water heater element is no longer able to stay hot because it is receiving less current now that the secondary load is in parallel with the water heater primary load 2015 Sensata Technologies Page 19 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 H watts max and the RE source must be limited to 10 below the continuous power of the battery based inverter used For MS PAE Series inverters the MS4024PAE is limited to lt 3600 watts and the MS4448PAE is limited to lt 4000 watts Power Resistors Ohms Watts Part Number Manufacturer Resistor assemblies listed above are manufactured by IPC Power Resistors Inc www ipcresistors com and Powerohm Resistors Inc www powerohm com Available resistor assembly options from these companies include an overtemperature switch auxiliary terminal blocks and custom enclosures Water Heaters Size Watts Part Number Manufacturer 28 Gallon 3500 E2F30LD035V Whirlpool 30 Gallon 3500 E2F30HD035V Whirlpool Air Heaters Resistor Boxes Watts Part Number Manufacturer Baseboard Heaters Watts Part Number Manufacturer 2500 8F2025 25
63. r is regulated on the AC side 2015 Sensata Technologies Page 5 Introduction 1 5 ACLD Features and Benefits 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 Inverter Connection Port orange a RJ11 port for connecting the ACLD controller to the network port green on a the MS PAE Series inverter Network Connection Port green a RJ11 port for connecting the ACLD controller to a Network controlled device i e ME BMK ME AGS N Knockouts four dual knockouts Y2 and 34 to accommodate AC wiring access and routing Info Four additional dual knockouts Y2 and 34 identical to the ones noted in Item 4 are located on the opposite side eight dual knockouts total Intake Cooling Fan an intake fan to pull in air to allow the ACLD controller to operate continuously at full power e 9 Status LED Inverter Network Indicator Connection Port Connection Port Dual Knockouts Intake V2 and 34 Cooling Fan Figure 1 3 Intake Fan Status LED Connection Ports and Knockouts Page 6 2015 Sensata Technologies Introduction The right side of the ACLD controller has an information label exhaust vents and an ON OFF switch see Figure 1 4 Information
64. r and charge the battery bank The MS PAE Series inverter communicates to the ACLD controller that it is charging causing the controller to return to Inactive mode Info While in the Float regulation stage either Standby Float or Active Float if the H batteries fall to the rebulk voltage level 25 6 VDC 24 volt systems or 51 2 VDC 48 volt systems another Bulk Absorption Charge stage will start After the Absorption stage is finished the ACLD allows the voltage to fall to the Float stage again This Float to Bulk to Absorb and back to Float cycle continues as long as it is required to ensure the batteries are continuously charged Info The secondary load is used as a back up to the primary load and must be sized H to absorb the full power output from the renewable energy source without turning off It must be available and always stay on can not turn off in case the primary load happens to turn off or is no longer available I nfo During the Standby and Active modes the ACLD uses the same Absorb and Float H voltage regulation setpoints that the MS PAE Series inverter uses while charging These regulation setpoints change based on temperature when a BTS Battery Temperature Sensor is connected to the inverter With a BTS connected the actual voltage level increases if the temperature around the BTS is below 77 F 25 C and decreases if higher than 77 F 25 C This ensures the batteries receive the correct voltage level regardl
65. rn shipment to the original purchaser whichever is greater All replaced products and parts removed from the repaired products become the property of Sensata This limited warranty is voided if e the product has been modified without authorization e the serial number has been altered or removed e the product has been damaged from abuse neglect accident high voltage or corrosion e the product was not installed and operated according to the owner s manual B 2 How to Receive Repair Service If your product requires warranty service or repair contact either An authorized service center listed on the http magnum dimensions com website or Sensata Technologies Magnum Dimensions Products at Phone 425 353 8833 Fax 425 353 8390 Email MagnumWarranty Sensata com If returning the product directly to Sensata Technologies for repair you must 1 Return the unit in the original or equivalent shipping container Note When shipping your product please ensure it is properly packaged Damage due to inadequate packaging is not covered under warranty We recommend sending the product by traceable or insured service Receive a Return Materials Authorization RMA number from the factory prior to the return of the product to Sensata Technologies for repair Place RMA numbers clearly on the shipping container or on the packing slip BEFORE RETURNING ANY UNIT TO SENSATA TECHNOLOGIES A RETURN MATERIAL AUTHORIZATION RMA NUMBER IS REQUIRE
66. s 6 r1 avo1 AuvhIud 8 z1 avo1 AUvhIud 4 TANVd 9nS 1V21419313 9 TaNvd ans 1V91419173 S 1VYLNIN NOWWOD t WULNAN NOWWOD T1 LNO LOH YALYSANI Z 71 LNO LOH YALYSANI T 40 WIN ue pej orguo uo ulewa je13souuau1 SAEMIE peo jsnuJ AJeuulJd peo MAP Ajepuooss e J9 0 3u05 UOISISAIG O d 12V 2015 Sensata Technologies Page 16 Installation Inverter AC Terminal Block Input and Output Wiring MS PAE Inverter Charger on MMPxxx 30D Enclosure ran Main Pavel LEG 2 2IN rae Main Panel Main Panel J with hood and backplate INV ea as OUT Ea7 iki to Sub Pauel via ACLD Sub Pand via Aci 3 rem Main Dane NEUTRAL gt rem Main Dane Main Panel m to Sut Pand via ACLD NEUTRAL to Sut Pand via ACLD ane via Aco of 5 INV HOT 2 gt OUT to Sub Panel via ACLD ACLD 40 Diversion Controller MMPxxx 30D AC Terminal Block Input and Output Wiring E SUB PANEL LEG 1 to Sub Panel AC Loads LI SUB PANEL LEG 2 to Sub Panel AC Loads JS INV HOT 2 IN from Main Panel INV HOT 1 IN from Main Panel ACLD Terminal Block Input and Output Wiring INV NEUTRAL IN from Main Panel Figure 2 7 AC Wiring from Inverter to ACLD 2015 Sensata Technologies Page 17 Installation 2 8 Wiring the ACLD The following steps ar
67. s lt 25 6 VDC 24v inverters or lt 51 2 VDC 48v inverter the ACLD initiates the Bulk stage i e Standby Bulk If the battery voltage is high 212 9 VDC 12v inverters 225 7 24v inverters or 251 3 48v inverters the ACLD will skip the Bulk and Absorb stages and go directly to the Float stage i e Standby Float During Standby mode the ACLD will be in one of the following regulation stages Standby Bulk The battery voltage is below the Absorb Voltage setting and remains in the Bulk stage until the battery voltage has reached the Absorb Voltage setting Standby Absorb The battery voltage has reached the Absorb Voltage setting and remains in the Absorb stage until the Absorb Time Done setting has been satisfied Standby Float The battery voltage is in the Float stage and remains in this stage unless the battery voltage falls to a low voltage which will start another Bulk Charge stage Active In the Active mode the ACLD is actively diverting excess current from the renewable energy source to regulate the battery voltage by connecting external diversion loads During Active mode the ACLD will be in one of the following regulation stages Active Bulk If the battery voltage begins rising quickly the ACLD activates and starts diverting current in an attempt to keep the voltage from rising above the absorb voltage setting The ACLD remains in the Bulk stage until the battery voltage has reached the Absorb
68. s means there may be more power generated than the critical loads can consume causing current to be pushed back into the inverter s AC output then to the battery bank causing the battery voltage to rise As the battery voltage rises and the battery becomes fully charged or the battery voltage starts to increase above the regulation setpoints the ACLD exits Standby mode and enters Active mode In Active mode the ACLD uses Pulse Width Modulation PWM regulation to control how much current from the renewable energy source is allowed to flow into the diversion load to keep the battery voltage from rising further As the battery s current requirements change the PWM switch inside the ACLD either closes for longer periods of time higher duty cycle to direct more current to the diversion load or closes for shorter periods of time lower duty cycle to decrease the current flow to the diversion load which allows more current to flow into the battery Once the battery is fully charged the PWM switch fully closes causing all the current produced by the renewable energy source to be diverted to the diversion load When the current is no longer required to be diverted away from the battery the PWM switch fully opens and causes the ACLD to exit Active mode and return again to Standby mode to start monitoring the battery voltage i Info When the MS PAE Series inverter is first turned on its automatic Search feature 2015 Sensata Technologies Page
69. se Width Modulation voltage prevents AC line disturbance by providing smooth transition when regulating e Allows the use of resistive AC household loads i e water heater tanks instead of expensive and hard to find DC loads to divert excess current e Does not require additional external sensors to monitor battery inverter output current battery voltage or battery type 1 1 What is an AC Load Diversion Controller ACLD The basic operating concept of an AC or DC diversion controller is quite simple Monitor the battery bank and if an energy source e g solar panel wind generator etc should cause the battery to rise to a predetermined voltage level connect a diversion load of sufficient size to prevent the battery from being overcharged By diverting the unused energy that your solar panel or wind generator is producing you can make use of it such as heating a hot water or heating a room The ACLD 40 is an AC load diversion controller that maximizes the use of onsite generated power i e renewable energy by diverting any excess energy to resistive loads on the AC side By diverting the excess current on the AC side and not on the DC side through the battery based inverter there is less strain on the battery based inverter Also since the wiring is on the AC side there is less voltage drop less expensive system wires and diversion loads and fewer issues when trying to determine how to size the diversion loads hardware
70. se compound into the electrical ports as shown in Figure 1 3 Items 2 and 3 Before installing the cables or if leaving any ports open squirt a liberal amount into each port Silicone dielectric compound makes an effective moisture and corrosive barrier to help protect and prevent corrosion to the RJ11 connections H I nfo If the controller is installed in an area where moisture may occur we recommend Cool The controller should be protected from direct sun exposure or equipment that produces extreme heat If the ambient temperature around the controller exceeds 77 F 25 C the power specifications are reduced Ventilation In order for the controller to provide full output power and to avoid over temperature fault conditions do not cover or block the controller s ventilation openings or install this controller in an area with limited airflow The controller uses a fan to provide forced air cooling this fan pulls in air through the intake opening see Figure 1 3 Item 5 and blows out air through the exhaust vents see Figure 1 4 Item 7 Allow at the minimum an airspace clearance of 6 15 2 cm at the intake and exhaust vents and 3 7 6 cm everywhere else to provide adequate ventilation Safe Keep any flammable combustible material i e paper cloth plastic etc that may be ignited by heat sparks or flames at a minimum distance of 2 feet 61 cm from the controller Have access to the MS PAE Series inverter The communica
71. spection 1 Verify all wire runs are secured If using strain relief clamps on the knockouts tighten the strain relief clamp securely on the wires Always leave a little extra slack in the wiring 2 Verify that all connections are correct and secure all the ACLD terminal screws are torqued to a maximum tightening torque of 16 Ibf in 2 0 N m and the ground screws are torqued based on Table 2 1 3 Replace the ACLD wiring access cover and any other cover you removed to access wiring terminals during this installation i e on the electrical distribution sub panel etc Page 18 2015 Sensata Technologies Installation 2 9 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 The diversion load connected to the ACLD must e handle 240VRMS e be pure resistive e sized a minimum of 110 of the renewable energy source e rated no less than 2500 watts and no greater than 5000 watts CAUTION Do not use light bulbs motors or other electrical devices for diversion N loads They are not stable and may be damaged or fail causing the battery to be overcharged Only purely resistive heating elements such as Wire wound resist
72. t and the MS PAE Series inverter is inverting the ACLD is in Standby mode and ready to regulate the charge current to the battery Figure 3 5 Utility not Connected Additional Power Provided to Critical Loads 2015 Sensata Technologies Page 27 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 Utility Not Connected Excess Current Charging Battery Bank Critical AC Loads less than Renewable Energy so battery bank is charging Renewable XT DT D DIR DC C J Battery Bank Battery E Increasing im Note When the utility power is lost and the MS PAE Series inverter is inverting the ACLD is in Standby mode and ready to regulate the charge current to the battery Grid Tie Inverter av MS PAE Series Inverter ay Main Household Loads Critical Loads ACLD Controller
73. tage Toujours v rifier le c blage avant de mettre sur le ACLD Utilisez des fils de cuivre seulement avec une cote de temp rature minimale de 75 C 167 F AC c blage ne doit pas tre inf rieure a 10 AWG 5 3 mm de cuivre de calibre Serrer toutes les connexions de c blage ca aux valeurs requises Le ACLD doit tre correctement mont voir la Section 2 3 Montage du ACLD dans ce manuel Protection pour le c blage de sortie AC contre les surintensit s n est pas inclus dans le ACLD et doivent tre fournis dans le cadre de l installation du syst me Reportez vous la Section 2 8 Cablage du ACLD pour plus d informations Le conducteur de sortie CA neutre n est pas connect coll sur le ch ssis ACLD la fois l entr e et la sortie des conducteurs sont isol s du ch ssis ACLD Sol si n cessaire est de la responsabilit de l installateur du syst me et doit tre conforme aux codes locaux et nationaux et des normes lectriques 2015 Sensata Technologies Page iii Table of Contents LO TEP OGU CCGA eonsisesasbsasviekrzvi acea ne nt mana CPUS KE VE PEFEREFEPERE EU 1 1 1 What is an AC Load Diversion Controller ACLD 1 1 2 What is an AC Coupled system and why do I need an ACLD 1 1 3 How an AC Coupled System Works Y 2 1 4 Battery Regulation Methods r
74. ted or coupled to the battery or DC side of the inverter In a DC coupled system the renewable energy is wired at a lower voltage to better match the battery bank and a DC controller is used to manage the energy to prevent the battery from being overcharged This type of system is usually more costly and complex to install because of more components and because the voltage is lower there are more efficiency losses as a whole when compared to a grid tie inverter only system However using a concept known as AC Coupling a four quadrant bi directional battery based inverter such as Sensata s MS PAE Series can be installed that utilizes the renewable energy to power the home s critical loads during a power outage from the AC side With the addition of a battery bank a critical loads sub panel and a diversion controller with load coupling a MS PAE Series inverter on the AC side can be very advantageous The existing renewable energy system does not need to be rewired to the DC side and the high conversion efficiency of the grid tie inverter is maintained while the utility power is available 1 3 How an AC Coupled System Works Described below is how an AC Coupled system works when utility power is available and when there is an utility power outage When utility power is available see Figure 1 1 Normally when utility power is available and a MS PAE Series inverter is installed the grid tie inverter converts the renewable
75. tions control for the ACLD is provided by the MS PAE Series inverter so the ACLD controller must be in an area that allows the network cable to be connected to the inverter The network cable provided is 6 and can be extended up to a length of 200 feet without data degradation See Section 2 10 1 for more information on the cable Accessible Do not block access to the controller s inverter and network ports as well as the ON OFF switch and status indicator Allow enough room to access the AC wiring terminals and connections as they will need to be checked and tightened periodically Away from sensitive electronic equipment High powered devices with PWM circuitry can generate levels of RFI Radio Frequency Interference Locate any electronic equipment susceptible to radio frequency and electromagnetic interference as far from the controller as possible 2 2 1 Conduit Knockouts The ACLD controller comes standard with four dual knockouts for 1 2 and 3 4 conduits on each side eight total Figure 1 3 shows the location of these conduit knockouts Select the appropriate knockout that is close to the terminal that the wire will connect to or whichever one works for the way your field wiring comes in Info The knockouts can be easily removed by tapping the edge with a straight bladed screwdriver and a hammer then twist out with pliers See Figure 2 2 Before removing any knockouts and mounting the ACLD controller think about whether you ar
76. ttery Note This frequency shift feature is enabled by setting the battery type to custom using a remote control however this feature should only be used as a backup the ACLD 40 should be used as the primary regulation method e A diversion load must be connected to the ACLD to prevent over charge damage to the inverter s battery bank It must be at least 10 larger than the maximum power rating of the renewable energy source See Section 2 9 for information on the ACLD load requirements e Asthe AC current is being provided by the grid tie inverter through the sub panel i e critical loads panel into the ACLD a 30 amp branch rated circuit breaker must be provided from the sub panel to the ACLD Note The installation can be made easier by using the MMP 30D Series enclosure This enclosure provides the required 30 amp overcurrent circuit protection between the sub panel and the ACLD controller e 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 2 1 2 Unpacking and Inspection Carefully remove the ACLD controller from its shipping container and inspect all contents Verify the following items are included e The ACLD Controller e 6 yellow communications cable e ACLD Owner s Manual e Access panel with hardware If items appear to be m
77. ugh you plan in the beginning the better the chances are that the installation will go well licensed or certified electrician It is the installer s responsibility to determine which Safety codes apply and to ensure that all applicable installation requirements are followed Applicable installation codes vary depending on the specific location and application of the installation f WARNING Installations should be performed by qualified personnel such as a WARNI NG Review the Important Product Safety Information on pages ii v before any installation CAUTI ON The ACLD controller weighs 20 Ib 9 1 kg use proper lifting techniques during installation to prevent personal injury I nfo The ACLD controller only controls the renewable energy source connected to the AC side of the system Any renewable energy source connected to the DC side of the system must be controlled separately using a DC controller diversion load 2 1 Pre Installation The simplified system diagram shown in Figure 2 1 should be reviewed to assist you in planning and designing your installation This drawing is not intended to override or restrict any national or local electrical codes This drawing should not be the determining factor as to whether the installation is compliant that is the responsibility of the electrician and the onsite inspector gt gt Battery Grid Bank Power Critical Loads Sub Panel Mini Magnum Main Loads Panel Main Panel
78. ult a very high AC voltage gt 275 VAC has been detected on the AC input Remedy This fault automatically clears once the AC input voltage to the ACLD falls below 260 VAC Blinks On 4 times then off four seconds No Load Fault no loads detected on either output terminals detected by minimum current flow to loads Remedy Check to ensure that the loads are rated for 240 VAC sized correctly see Section M 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 40 of J 6900 7 Y EN Use an ohmmeter to check resistance 0 from terminal 7 to 8 primary load qe then from terminal 9 to 10 secondary Primary load The resistance for each load connected should be 10 15 ohms e QC FUSED CAUTI ON Ensure all power to the C ACLD is removed prior to checking the load resistance or damage to Secondary Ohmmeter the ohmmeter may occur Load Figure 3 11 Checking Load Resistance 2015 Sensata Technologies Page 33 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 f
79. ure 3 11 Cneckirid boad ResiSEaliC B a dada se danses xut Dataqotes Kw ne became 33 List of Tables Table 2 1 Torque Values for Ground Busbar eese nane nnn 14 Table 2 2 Torque Values for the AC Terminal Blocks nmm 14 Table 3 1 LED Blinks to Fault Condition ananas dan DH EINE MAS UE RICE RN 32 2015 Sensata Technologies Page v Page vi 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 The ACLD 40 controller includes the following features e Automatic three stage battery regulation with adjustable voltage and charging parameters e Controls up to 4000 watts of excess power to prevent battery overcharge e Automatic battery temperature compensation provides optimum charging even during extreme temperature changes when using the inverter s Battery Temperature Sensor e A networked diversion device using inverter and network ports e ON OFF mounted switch with status fault indicator LED operation and power information is provided when using the inverter s remote e Designed to work with MS PAE Series inverters to prevent battery overcharging e Diversion load is isolated from in home AC loads and receives PWM Pul
80. ust be no less than 10 AWG 5 3 mm gauge copper wire and be approved for the application i e residential wiring e he wire sizes recommended in this manual are based on the ampacities given in Table 310 16 in conduit or Table 310 17 in free air of the NEC ANSI NFPA 70 for 75 C 167 F copper wire based on an ambient temperature of 30 C 86 F 2 4 3 Wire Routing Before connecting any wires determine all wire routes to and from the load controller Typical routing scenarios are e Network communication cable from the inverter to the load controller e AC wiring from the inverter output to the load controller e AC wiring from the load controller to circuit protection if not using the MMP enclosure e ACwiring from the circuit protection or MMP enclosure to the AC sub panel i e dedicated inverter circuits e AC output wiring from the load controller to the primary diversion load which can be configured to turn off e AC output wiring from the load controller to the secondary diversion load which must be configured to always be available and stay on e Ground wiring to and from the load controller e Remote control cable to the inverter 2015 Sensata Technologies Page 13 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 hand

Download Pdf Manuals

Related Search

Related Contents

Hygiena SureTrend User Manual V4.0  消費生活だよりNo.13（平成25年6月発行） （PDF：946KB）  atrazine 480 herbicide commercial lire l`étiquette et le dépliant  L`adaptation de l`intervention auprès des personnes  Altronix AL175UL power extension  EXT-CAT5-9500HD X1.indd  Vestax PMC-270A Musical Instrument User Manual  Instruction Manual  User Manual, AED10 Automatic External  SE57BR-LG 共通  

Copyright © All rights reserved. Failed to retrieve file