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2016
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DC relays for solar panels

DC to DC relay   DC power relay
250VDC    25 amp                        400VDC  200 amp

These are the big boys
Connect big volts and amps to the contacts
Operate the coil using 12-24 Volt DC

DC to DC relay/ mechanical type

240 Volt DC power relay /26 amp to 200 amp DC

Full on-off contacts/ 12 or 24 volt DC coil
250 volt / 25 amp DC load
250V x 25 amp = 6250 watt
Connect 12 or 24 volt DC to terminals 3-4;
Connect load to terminals 1-2

Buy:
Electromechanical DC-DC G9EB-1 relay
G9EB-1-B-DC24
24 VDC coil and 400 VDC/ 200 amp contacts
Omron relay at online
Fuseholder

Resources:
Omron-DC-DC-relay-Datasheet
Omron DC-DC pdf
DC power relay spec sheet
Convert AC water heater to DC water heater
Dave says
Normal power relays burn up when they are fed DC power instead of the AC power they are rated at.   Relays can be delicate.:
I had an issue with relays in my controller box getting destroyed when I switched elements between 240VAC and 120VAC. I solved the issue by turning off the power relay (DPST relay) feeding the 120/240 selection relay (SPDT relay), then flipping 120/240 relay state, then turning the power relay back on.   I figured the arc flash between the N and Hot side of the DPST relay was being aided and abetted by the armature moving between contacts while under power.

Gene:
Blowout relay
Magnetic blowout relay
DC relay
90 mm tall x 50 mm wide/ 25.4 mm per inch
3.5" tall x 1" wide

Electric vehicle motor controller/ DC contactor

Electric vehicle DC relay
Normally closed (normally ON ... must activate to turn OFF)
Contacts With blowouts 96 volt max 250 Amp
48 volt max 250 amp
Rated 1 million cycles

Resource:
http://www.schaltbau-gmbh.com/en/Products/Contactors/
AFS series
C110B series
Specification sheet/ pdf

Electric vehicle motor controller

Load contacts: 96 volts DC 200 amp DC
96 volts @ 250 amp
http://www.dccontactors.com/Contactors_and_Kits.html
http://www.schaltbau-gmbh.com/en/Products/Contactors/
28 volt 30 amp dc relay

Load Contacts: 28 volt DC 30 amp DC

9A seriesW9AS1D52-110/ 30 amp @ 28 volt DC
W9AS5D52-110/ 30 amp @ 28 volt DC
Online
Magnecraft power relays
Schneider power relays
28 Volt 50 amp DC relay
Coil 12-24 VDC
Load contacts 26 VDC  40-50 Amp

12 Volt DC coil/ power relay

Load Contacts: 28 VDC 40-50 amp DC

Buy:
24 volt DC coil/ 40 amp @ 26 VDC
12 volt DC coil/ 40 amp @ 26 VDC
6 volt DC coil/ 40 amp @ 26 VDC
110 volt DC coil/ 40 amp @ 26 VDC
W199AX-3 relay
W199PX-13/ 50 amp at 26 VDC = 1400 watt
X199 Magnecraft relay
Magnecraft W199 DC relay

Resource:
Magnecraft relay / pdf
Resource
relay cover

Box and cover for heavy-duty magnecraft relay

Magnecraft relay with NO NC terminals 120 volt coil or 24 volt coil

Buy from my affiliate links
Magnecraft 50-1289-1 relay box and cover

Resources:
How to reverse motor with switch
Difference between contactor and relay
Relays for DC motors and solar panels
Control motor with 2 switches
Start two motors at different times
200 amp DC relay

DC relay/ automotive / Input voltage 12 Volt DC

Contacts: 12 Volt DC /  200 amp DC

4 gauge wire
Buy:
12 volt 200 amp relay at Amazon
Resources:
200 amp DC relay
More high amp 12 Volt DC relays

24 Volt DC coil

Contacts 90 amp AC/ 3-pole + 1NO/1NC

Buy:
Dayton 6ECD9 at Amazon
DC relay

DC relay/ Input 3-28 Volt DC

Contacts: 120 Volt AC / 26 amps

Buy:
3-32 volt DC input/ control 120 Volt 25 amp AC
Opto relays at Amazon

Resources:
Solid state relay data sheet
Solid state relay DC relay data sheet
3-phase solid state relay

DC relay/ Input 3-32 VDC

Contacts 3-phase 25A AC 480 volt

Buy:
3-phase solid state relay at Amazon
DCP200 relay

DC200P 5-200 VDC solid state relay

Contacts: 24 VDC 1 amp DC


Buy:
DC200P 200 volt DC at Amazon
Opto relays at Amazon

Resources:
Solid state relay data sheet
Solid state relay DC relay data sheet
DC60MP solid state DC relay

DC60MP 5-60 VDC solid state relay

Contacts: 24 VDC 3 amp DC

Buy:
DC60MP 60 volt DC at Amazon
Opto relays at Amazon

Resources:
Solid state relay data sheet
Solid state relay DC relay data sheet

DC to DC solid state relays

Buy from my associate links
100 volt 25 amp DC Relay
200 volt 25 amp DC relay at Amazon

Relay safety cover
Heat sink

Resource:
Convert water heater from AC to DC
Electromechanical relay vrs solid state relay/ pdf
Switching function solid state relay/ pdf
CN101A timer wiring
Larger image/ amico timer with dust cover

dust cover for amico timer
Dust cover

CN101 timer/ 12 VDC input

Contacts: 12 VDC 16 amp DC

7 day 17 on-off settings
12-24 Volt DC programmable timer

Buy from my associate links:
Amico 120 volt 7-day timer
12 Volt/ 16 amp/ DC timer at Amazon
CN101 12VDC timer at Amazon
24 Volt/ 16 amp/  DC timer at Amazon
Dust cover for Amico timers at Amazon
Amico timers at Amazon
Transformer: 120-240 Volt to selectable DC voltage

Resources:
CN101A/ amico timer manual/ pdf with wiring
How to wire amico timer
Terminals
30 amp DC safety switch

30-60 amp DC safety switches/ fusable

Heavy Duty 250 V Dc Voltage; 30 Ampere
Buy:
Square D 30 amp DC HU361RB
Square D 60 amp DC H222AWK

Resource:
DC safety switches
Generic: How to wire safety switch
Convert AC water heater to DC water heater
DC relays for solar power
ST3PF off delay timer

12 VDC/ 0-3 minute delay timer

Contact rating: 12 VDC 3 amp DC

Buy:
12 volt DC relay
12 volt dc relays at Amazon
Photovoltaic water heater
Connect DC directly to water heater

Photovoltaic water heater

Electric Solar panel connected to electric water heater

If solar panels deliver enough Kw, then the water heater thermostats will melt
AC rated elements will work with DC.
Ordinary water heater elements will work with DC power
Ordinary water heater thermostats will melt with DC power
Buy from my associate links:
Elements at Amazon
DC Element at Amazon

Quote: "a photovoltaic water heating (PVWH) system requires neither a battery for energy storage nor an inverter to convert the DC power supplied by the photovoltaic array into an alternating current (AC) power. The DC power supplied by the photovoltaic array is fed to one or more resistive elements that are immersed in a water storage tank."
Resource:
How to convert AC water heater to DC
DC solar water heater

Question:
Is it worth replacing $100-200 contactor or relay each year or two just to make a direct DC water heater vrs converting DC to AC as is typical? Cost analysis not known.

Dave says:
Omron is cheap relative to the the cost of the solar modules.     I think PV direct water heater is still in the game

Resource:
How to convert AC water heater to DC
Omron DC-DC relay shown at top of page is best.
3-pole 90 amp AC with 120 volt coil is next best.

**************************
The 48 volt DC 100 amp selling for $100 on Amazon... is same-similar to golf cart DC solenoid and same price.
Maybe it will work for diagram on left but not full-blown DC water heater

++++++++++++++++++
Called golf cart guy:
Golf cart guy said his 48 volt solenoid will burn out with 96 volts or more.

*******************
Golf cart guy says they replace DC solenoids each 5 years on golf cart...each round of golf you turn cart on-off 40-50 times... you play golf 40 times per year ... so we might estimate a DC relay is good for 2000-4000 activations.

Can we get same service from 3 pole AC contactor? NO?
Can we get same service from Omron DC-DC relay? Spec sheet says Yes

**************************
Called auto salvage yard... no such animal as DC solenoid unless yard has hybrid or electric car ... very little demand for electric or hybrid car parts...  because repairs are done at dealer.... dealer orders parts from original builder of car who got parts special made for that car.
No parts left, no repair.
Dealer DC parts would be costly.

******************
The others relays-contactors are too small for direct DC solar water heater

*****************
Called DC contactor manufacturer:
Salesman very knowledgeable ...
They do not sell very many DC contactors... and he laughed .... indicating the demand must be miserable... and he didn't have a price.
They do not stock them. They manufacture those contators to order.
They stock the UPS contactor... same rating as golf cart solenoid.
Too small for full blown DC water heater

***************
Discovered:
Manufacturer's can make a DC contactor to exact specification.... wsalesman can put together a quote for 100 pieces.

******************
Conclusion:
If a big company can find profit making DC solar water heater... then the relay will be manufactured,
... and parts available off-the-shelf?
Outlook seemed unlikely among folks I spoke with.
But history never travels straight line... DC water heater invention is viable if Omron is available and works reliably.



Multimeter

Test for breaks in wire/ Test for voltage
Most appliance require 80% rated voltage to function correctly
Buy:
Multimeters at Amazon
Electric testers at Amazon 
Resource:
How to test and replace element
How to test thermocouple
Element tests for 120 volts
How to test wire
Safety when testing wires:
Never touch wet or previously flooded appliance.
Never stand on wet surface when working on electric.
Never stand on bare soil, put down dry boards.
Tape tester leads to wood sticks to keep hands away from power.
Use non-contact voltage tester before touching wires.
Never touch or lean into any made of metal.
Remove metal objects from pockets.
Do not use oxygen or fuel accelerants in same room as electrcial repairs

Resource:
Basic house wiring

Non-contact voltage tester

Test for power without touching connectorss
NEVER assume power is OFF
Buy:

Non-contact voltage tester Amazon
Electric testers at Amazon
 
Resource:
How to test electric power is off

Resource:
How to install terminals
Treminals

Terminals

Buy:
Terminal kit
Blue for 16-14 wire
Yellow for 12-10 wire
Read about terminals
wire connector assortment

Twist-on wire connector assortments

Do not reuse old connectors 
Buy

Connector assortment at Amazon
Connector assortment at Amazon

Resource
How to select and install twist-on wire connectors
Weatherproof wire connector

Weatherproof wire connector

Connector cavity is full of silicone
Built-in cover keeps silicone in place
Protect from water, dust etc
Buy from my affiliate links
Weatherproof size 14 to 6 Amazon
Weatherproof size 22 to 8 Amazon

Resource
How to select and install twist-on wire connectors
Wire connector wrench

Wrench to apply wire connectors

Tighten connector 
Buy

Wire connector blaster
Twist connector wrenches at Amazon

Resources:
How to twist wire
How to select and install twist-on wire connectors
Push on wire connectors

Push-on wire connectors in place of twist-on connectors

Buy:
Push on wire connectors Amazon
Red 3P connector for 10-14 gauge wire
Lever connectors for stranded wire at Amazon
add solder to stranded wire

Turn stranded wire into solid wire

Add solder to 1" length of tightly twisted stranded wire to make into solid wire
Heat wire. Touch solder to wire. Let cool. File away over-solder.
Buy:
soldering guns
Resource

Timer caught fire

linesman pliers
Buy tools:
Wire strippers at Amazon
Linesman pliers
Utility knife at Amazon
End cutting nippers at Amazon

Fire inside timer caused by stranded wire
Keep enclosure door closed at all times

Fire caused by stranded wire

Do not use stranded wire under screw plate

Applies to timers, switches, outlets, pumps etc.
Small devices, with small loads, such as lamp socket, stranded wire is fine
Add solder to 1" length of tightly twisted stranded wire to make into solid wire
Heat wire. Touch solder to wire. Let cool. File away over-solder.
Buy:
soldering guns
Resource

Timer caught fire

Orange 10 gauge 30 amp


Orange/ #10 gauge for for 30 amp circuits including water heater
with ground
Buy:
10-2 gauge/ 30 amp
10-3/ 30 amp

NMB is house wiring
UF is underground

Yellow 12 gauge 20 amp


Yellow/ #12 gauge wire for 20 amp
with ground
Buy:
12-2 gauge/ 20 amp
12-3/ 20 amp

Rolls of stranded wire

NMB is house wiring
UF is underground
White 14 gauge 15 amp


White/ #14 gauge wire for 15 amp
with ground
Buy:
14-2 gauge/ 15 amp
14-3/ 15 amp

NMB is house wiring
UF is underground

Copper ground wire
Use same size as other wire in circuit

Buy
Spools of ground wire
Ground rods at Amazon

Basic household wiring
Basic water heater circuit

Figure volts amps watts for electric water heater
Test elements
Replace elements
How to wire tankless electric
How to change water heater temperature using timer
Change water heater from 240Volt to 120Volt
Replace thermostats
How to wire thermostats
How to wire water heater for off peak operation

How to twist wire
How to wire Cooper 277 pilot light switch
How to wire combo switch-outlet
How to replace 3-speed fan switch
 

How to wire dimmer
How to wire 3-way dimmer
How to wire occupancy switch
How to wire motion detector
How to wire TM811 and TM8111 switches
How to wire wall timers
How to wire box timers
How to wire off-delay timer
Wire off-delay timer
How to wire pin timers

How to wire and troubleshoot photo eyes
Reverse photoeye so it turns on in day
24 Volt photoeye
24 volt programmable timer

How to wire switches
How to add switch
How to add 3-way switch


Timer for 3-way switch
Timer for 4-way switch

How to add outlet 
How to wire 3-way switches
How to wire 4-way switches


Troubleshoot Malibu outdoor lights
Terminals 
Select and install wire connectors
Select wire size

Electrical formulas
Electricians forum
 

Electrical pages


How to wire arc fault breaker
How to wire GFCI
How to wire GFCI combo

Basic water heater circuit
How to wire water heater for 120Volt
Install old work box

How to drop wire from attic
Wire connector

How to wire 240volt outlets
How to install 3-phase timer
How to wire 3-phase outlets
How to wire 3-phase surge protector
What is 3-phase

How to wire whole house surge protector
How to wire under-counter water heater
 

See inside main breaker box
Replace breaker
Install subpanel

Fuseholder
Contactors
How to solder wires
Whole house surge protector
3-phase surge protection
Circuit breakers

Difference between 120 volt and 240 Volt
Difference between 50Hz and 60Hz
How to install electric meter on water heater
How to wire water heater thermostat
How to wire water heater with switches and timers

6x6x4 Enclosures
Intermatic timer enclosures

Convert AC water heater to DC
How to wire DC solar water heater
DC relays for solar water heater
How to add another thermostat to water heater

How many Kwh to heat water
Chart for figuring heating time for electric heater
Gas and electric water heaters Buy:
Industrial electric at Amazon


Industrial supplies at Amazon

Industrial and scientific Amazon
Intermatic control centers Intermatic control centers:
+ manuals and parts


Including Z-wave
box timers Compare box timers

Control with Z-wave
programmable timer Compare programmable timers

Control water heater with programmable wall timer
Countdown timers Compare countdown timers

Control water heater with countdown timer
Compare power packs

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