ACLD-40 AC Load Diversion Controller - 4.
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.
Safety Information IMPORTANT PRODUCT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR THE ACLD-40 CONTROLLER THAT SHALL BE FOLLOWED DURING THE INSTALLATION AND OPERATION OF THIS PRODUCT. Before using the ACLD, read all instructions and cautionary markings. Also, be sure to follow the instructions provided for each component of the system. Do not perform any installation or service described in this owner’s manual unless properly trained and capable.
Safety Information CONSIGNES DE SÉCURITÉ IMPORTANTES CONSERVER CES INSTRUCTIONS CE MANUEL CONTIENT DES INSTRUCTIONS IMPORTANTES POUR LE CONTRÔLEUR ACLD-40 AU COURS DE L’INSTALLATION ET FONCTIONNEMENT DU PRODUCT. Before utilisant le ACLD, lire toutes les instructions et mises en garde. Aussi, assurez-vous de suivre les instructions fournies pour chaque composant du système. Ne pas effectuer toute installation ou service décrit dans le manuel du propriétaire, à moins bien formé et capable.
Table of Contents 1.0 Introduction ............................................................................. 1 2.0 Installation .............................................................................. 8 3.0 Operation ............................................................................... 23 4.0 Troubleshooting ..................................................................... 33 1.1 1.2 1.3 1.4 1.5 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.
List of Figures Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1-1, ACLD Inactive (Utility Power Available) ............................................................ 2 1-2, ACLD Active (Utility Power NOT Available)........................................................ 3 1-3, Intake Fan, Status LED, Connection Ports, and Knockouts ..................................
Page vi © 2015 Sensata Technologies
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 Series1 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: • • • • • • • • • 1.1 Automatic three-stage battery regulation (with adjustable voltage and charging parameters).
Introduction Traditionally, when a battery-based inverter is used, the renewable energy system is connected 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.
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.
Introduction 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.
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: • Generated power from the renewable energy is limited/wasted during the frequency shift. • Batteries are cycled, not regulated—does not allow the batteries to get properly charged1.
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): 1 Status LED Indicator – this green LED illuminates to provide operation and fault information on the ACLD controller. 2 Inverter Connection Port (orange) – a RJ11 port for connecting the ACLD controller to the network port (green) on a the MS-PAE Series inverter.
Introduction 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 vents are located on the right side and at the rear of the top side.
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 qualified personnel, such as a 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.
Installation 2.1.1 • • • • • • • Considerations when Installing the ACLD System The ACLD controller is designed to be connected and powered from the AC output of a batterybased 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.
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.
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.
Page 12 Left Side & ¾" 12" (30.5 cm) Top Side 11 ¼" (28.6 cm) 12 ¾" (32.4 cm) (x4) ½" Dual 6 ¾" Knockouts (17.1 cm) Ø.280 (0.71 cm) 4 places Exhaust Vents 5 ½" (14 cm) Right Side 6 ½" (16.5 cm) Intake Cooling Fan Front Side Figure 2-4, ACLD Dimensions and Side Reference 13 ⅝" (34.
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.
Installation 2.4.4 Wire Size and Overcurrent Protection The wiring must be approved for the application (i.e., residential wiring) and sized per the local electrical safety code requirements to ensure the wire’s ability to safely handle the maximum load current. The wiring must be protected from short circuits and overloads by an overcurrent protection device. This overcurrent protection device must have a means to disconnect the circuits (e.g.
Installation 2.6 ACLD Terminal Block Connections The ACLD controller has a ten-pole terminal block and a ground busbar to permanently connect the BBI/Battery Based Inverter (e.g., MS-PAE Series), the GTI/Grid-Tie Inverter and any primary or secondary loads (see Figure 2-5). To access and view the terminal block and ground busbar, remove the two Phillips screws holding the AC wiring access cover plate (see Figure 1-5, Item 9). Each connection on the terminal block is rated to accept one #14 to #6 AWG (2.
Page 16 Primary Load (thermostat controlled can turn off) R E T O R T E V IN Battery Management Secondary 4kW Load (must always remain on) 1 2 3 4 5 6 7 8 9 10 ACLD-40 Diversion Controller 1 2 3 4 5 6 7 8 9 10 = = = = = = = O N O N O N O F F O F F O F F N O N O N O N O F F O F F O F F O F F O Critical Loads Sub-Panel O N O F F OFF ON MS-PAE Inverter on MMP Enclosure REMOTE Remote Control O N O N O N O N O N O N O N O F F O F F O F F O F F O F F O F F O F F N O N O N O N O N O N
Installation Inverter AC Terminal Block (Input and Output Wiring) MS-PAE Inverter/Charger (on MMPxxx-30D Enclosure with hood and backplate) AC LEG 1 IN (from Main Panel) 1 AC LEG 2 IN (from Main Panel) 2 INV HOT 1 OUT (to Sub-Panel via ACLD) 3 AC NEUTRAL (from Main Panel) 4 AC NEUTRAL (to Sub-Panel via ACLD) 5 C INV HOT 2 OUT (to Sub-Panel via ACLD) 6 A B AC GROUNDS (to Sub Panel) ACLD-40 Diversion Controller 3 C AC NEUTRAL (to Sub-Panel Neutral) 4 D SUB-PANEL (LEG 1) (to Sub-Panel/A
Installation 2.8 Wiring the ACLD The following steps are basic guidelines for installing and connecting wiring to and from the ACLD controller. Refer to Figure 2-7 for visual guidance. Note: The instructions below refer to the ACLD’s terminals using the attached label terminology. Wiring the Inverter AC Output to the ACLD 1. 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.
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.
Installation 2.9.2 Compatible Diversion Loads Below is a list of compatible loads that may be used with the ACLD. Info: The diversion load must be sized at 110% or larger than the RE source (4800 watts max), and the RE source must be limited to 10% below the continuous power of the battery-based inverter used. For MS-PAE Series inverters, the MS4024PAE is limited to ≤3600 watts and the MS4448PAE is limited to ≤4000 watts.
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.
Installation 2.11 Using a Remote Control with the ACLD Controller A remote control display (ME-ARC, ME-RC11, or ME-RTR1) 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.
Operation 3.0 Operation 3.1 ACLD Operation Normally, when utility power is available, the grid-tie inverter in the system converts the renewable energy to AC that works in parallel with the utility to: power the load panels (main panel and subpanel 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,.
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.
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.
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.
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 MSPAE Series inverter, the grid-tie inverter reconnects and starts converting the renewable energy to power the critical loads (see Figure 3-4).
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).
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).
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 functions of an on/off switch and is a 20-amp circuit breaker that provides overload protection for wiring inside the load controller.
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.
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.
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.
Troubleshooting Troubleshooting Continued: • Blinks On 5 times then off four seconds - Desat (i.e. Desaturation) Fault; hardware saturation inside the controller has occurred—indicates a possible catastrophic failure. Remedy: This fault requires a reset of the ACLD. Press the ON/OFF switch on the side of the ACLD controller to remove power to the unit, and then press the ON/OFF switch again to restore power. If the fault recurs, contact Sensata for service.
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 & grid) Output Voltage (to load) Output Waveform (to load) 240 VAC ± 10% 0 - 240 VDC Full Rectified Sinewave Nominal Frequency Input 50 or 60 Hz Continuous Rated Power 4000 VA @ 25°C Continuous Rated Current Absolute Maximum Current (Input and Output to Loads) 20 amps AC @ 25°C 30 amps AC D
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 gridinteractive (also known as utility-interactive) device and does not have the capability to export (or sell) power back into the utility grid.
Appendix B – Warranty & 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.
Notes: Page 38 © 2015 Sensata Technologies
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.
