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Magnum Dimensions ACLD-40 Owner'S Manual Download Page 15

© 

2015 Sensata Technologies

Page 8

Installation

2.0 Installation

Read the entire Installation section to determine how best to install the ACLD controller. The more 

thorough you plan in the beginning, the better the chances are that the installation will go well.

WARNING:

 Installations should be performed by quali

fi

 ed personnel, such as a 

licensed or certi

fi

 ed 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 speci

fi

 c location and 

application of the installation.

WARNING:

 Review the “Important Product Safety Information” on pages ii-v before 

any installation.

CAUTION:

 The ACLD controller weighs 20 lb (9.1 kg), use proper lifting techniques 

during installation to prevent personal injury.

Info:

 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 simpli

fi

 ed 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.

MagNet 

Comm

ACLD-40

Load

Controller

Output

(to Pri load)

Output

(to Sec load)

Input

(from GTI)

Input

(from BBI)

Grid-Tie

Inverter (GTI)

Main Loads 

(Main Panel)

Battery

Bank

MS-PAE Series

-

Battery Based 

Inverter (BBI)

Critical Loads 

(Sub-Panel)

Grid

Power

Primary

Diversion Load

Mini Magnum

Panel

Secondary

Diversion Load

PV

Power

Figure 2-1, Simplifi ed ACLD System

Summary of Contents for ACLD-40

Page 1: ...ACLD 40 AC Load Diversion Controller 4 0kW Owner s Manual ...

Page 2: ...n 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 failure of that life support device or system or to affect the safety or effectiveness of that device or system If the ACLD ...

Page 3: ...is 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 ...

Page 4: ...çu pour l installation du compartiment intérieur Il ne doit pas être exposé à la pluie la neige l humidité ou des liquides de tout type Utiliser des outils isolés pour réduire le risque de choc électrique ou courts circuits accidentels Il n y a pas réparable par l utilisateur contenues dans ce produit Cet appareil est fourni avec une protection intégrale contre les surcharges Utiliser des méthodes...

Page 5: ... ACLD Load Requirements 19 2 10 Connecting the ACLD to a MS PAE Series Inverter 21 2 11 Using a Remote Control with the ACLD Controller 22 3 0 Operation 23 3 1 ACLD Operation 23 3 2 Three Stage Regulation 25 3 3 Operation Scenarios Utility Connected 26 3 4 Power Flow Scenarios Utility Not Connected 27 3 5 Power Switch Operation 30 3 6 Inverter Fan Operation 30 3 7 Operating Modes 31 3 8 Monitoring...

Page 6: ...ETWORK Communication Cable 21 Figure 3 1 Automatic 3 Stage Graph 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 Cur...

Page 7: ...Page vi 2015 Sensata Technologies ...

Page 8: ...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 ...

Page 9: ...nel 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 util...

Page 10: ...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 o...

Page 11: ... 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 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 ba...

Page 12: ...ing generated energy 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 sent to the dedicated diversion...

Page 13: ...es inverter 3 Network Connection Port green a RJ11 port for connecting the ACLD controller to a Network controlled device i e ME BMK ME AGS N 4 Knockouts four dual knockouts and to accommodate AC wiring access and routing Info Four additional dual knockouts and identical to the ones noted in Item 4 are located on the opposite side eight dual knockouts total 5 Intake Cooling Fan an intake fan to pu...

Page 14: ...ust Vents The right side of the ACLD controller has an information label exhaust vents and an ON OFF switch see Figure 1 4 6 Information Label includes model serial number information date of manufacture and specifications See the specifications in Appendix A for more information 7 Exhaust Vents ventilation openings that allow heated air to be removed by the internal cooling fan The exhaust air ve...

Page 15: ...o prevent personal injury Info 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...

Page 16: ...n 2 9 for information on the ACLD load requirements As the 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 circu...

Page 17: ...ovide 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 communications 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 t...

Page 18: ...it 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...

Page 19: ...e 2 4 ACLD Dimensions and Side Reference 0 71 cm 4 places Ø 280 Right Side Top Side 12 32 4 cm 11 28 6 cm 12 30 5 cm Exhaust Vents 6 16 5 cm Left Side Front Side Intake Cooling Fan 5 14 cm Dual Knockouts x4 6 17 1 cm Back Side Dual Knockouts x4 13 34 6 cm ...

Page 20: ...xisting electrical plumbing or other areas of potential damage prior to making cuts in structural surfaces or walls AC overcurrent protection must be provided as part of the installation and be properly sized Use only copper wires with a minimum temperature rating of 75 C 167 F Always use properly rated circuit breakers If using an electrical sub panel circuit breakers can be moved from the main e...

Page 21: ...tput 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 the ACLD s internal electronic overcurrent protection circuitry CAUTION The ACLD inte...

Page 22: ... and three 14 to 6 AWG 2 1 to 13 4 mm2 compression terminals with slotted head screws See Table 2 1 for torque requirements 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 sh...

Page 23: ...ve Inverter 240VAC 60Hz PV Array Disconnect PV Performance Meter Main Utility Panel Photovoltaic Array MS PAE Inverter on MMP Enclosure O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F O N O F F ON OFF 120 240VAC 60Hz REMOTE Remote Control INVERTER HOT OUT L2 INVERTER HOT OUT L1 COMMON NEUTRAL COMM...

Page 24: ...LOAD L2 to Diversion Load PRIMARY LOAD L1 to Diversion Load SECONDARY LOAD L2 to Diversion Load SECONDARY LOAD L1 to Diversion Load AC LEG 1 IN from Main Panel AC LEG 2 IN from Main Panel INV HOT 1 OUT to Sub Panel via ACLD AC NEUTRAL to Sub Panel via ACLD AC NEUTRAL from Main Panel INV HOT 2 OUT to Sub Panel via ACLD 3 9 8 7 6 5 4 2 1 3 6 5 4 2 1 E G INV HOT 2 OUT from ACLD to Sub Panel 6 5 4 3 2...

Page 25: ... 7 show the ACLD wired through a MMP 30D Series enclosure 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 ...

Page 26: ...s 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 load should be at least 4400 CAUTION To pr...

Page 27: ...m 12 3888 PR5505 16A PowerOhm 12 3888 PR4405 14 PowerOhm 12 3072 PR12R3K07 PowerOhm 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 Numbe...

Page 28: ... MS PAE Series Inverter Charger Connects to remote from REMOTE blue port connects to ACLD from NETWORK green port ACLD NETWORK cable REMOTE cable TO NETWORK port used to connect additional network accessories Figure 2 8 ACLD to Inverter Communications Cable Connection 1 2 3 4 1 2 3 4 TAB TAB same color same color 4 conductor telephone type opposite colors from top to bottom tabs facing toward you ...

Page 29: ...low the Absorb Voltage setting the frequency returns to 60 0Hz allowing the utility interactive inverter to reconnect Set the Absorb Time this setting is used to determine the time that the ACLD will regulate the battery at the absorption voltage 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 ...

Page 30: ...play 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 ...

Page 31: ...batteries are continuously charged Info The secondary load is used as a back up to the primary load and must be sized 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 Info During the Standby and Active modes the ACLD uses the same Absor...

Page 32: ... 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 ...

Page 33: ... Not powered Note When the MS PAE Series inverter is connected to the utility and charging the battery the ALCD is Inactive MagNet Control Figure 3 2 Utility Connected Surplus Power Fed to the Utility Grid Figure 3 3 Utility Connected Additional Power Provided by 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 ...

Page 34: ...ds Utility Grid Power Secondary Load Not Powered Primary Load Not Powered Relay PWM Switch MagNet Control Figure 3 4 Utility not Connected RE Powers Critical Loads Relay PWM Switch Grid Tie Inverter ACLD Controller Standby Renewable Energy MS PAE Series Inverter Battery Bank Battery Decreasing Critical Loads Utility Not Connected Additional Power Provided to Critical Loads Power to critical loads ...

Page 35: ...CLD is in Standby mode and ready to regulate the charge current to the battery Figure 3 6 Utility not Connected Excess Current Charging Battery Bank Relay PWM Switch Grid Tie Inverter ACLD Controller Active Renewable Energy MS PAE Series Inverter Battery Bank Battery Almost Full Critical Loads Utility Not Connected Diverting some Power to Primary Load ACLD connects primary load to divert some exce...

Page 36: ...y 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 Relay PWM Switch Grid Tie Inverter ACLD Controller Active Renewable Energy MS PAE Series Inverter Battery Bank Battery Full Critical Loads Ut...

Page 37: ... power switch is labeled with universal l and O symbols The l line symbol represents power on and the O circle symbol represents power off These symbols come from the binary system l 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 l to clear the fault and restart the load controller Info The...

Page 38: ...e 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 batter...

Page 39: ... 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 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 co...

Page 40: ...ed 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 Fault a very high AC voltage 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 ...

Page 41: ...nds 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 ...

Page 42: ...and Capabilities Temperature Compensated Regulation With BTS connected to inverter Internal Cooling Uses ball bearing fan for long life Integrated Electronic Protection Overcurrent and overtemperature Safety Listings ETL listed to UL cUL 1741 2nd edition CSA C22 2 No 107 1 01 Warranty Three years Five years when purchased with and installed on a MMP or MP enclosure system Operating Temperature 20 ...

Page 43: ...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 on the MagNet network either Ma...

Page 44: ...ale or itemized receipt 5 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 a...

Page 45: ...Page 38 2015 Sensata Technologies Notes ...

Page 46: ...gnum Dimensions Products Manufactured by Sensata Technologies 2211 West Casino Rd Everett WA 98204 Phone 425 353 8833 Fax 425 353 8390 Web www magnum dimensions com ACLD 40 Owner s Manual PN 64 0062 Rev A ...

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