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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 series W9AS1D52-110/ 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 amp
s
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
DC contactor 3-pole contactor wired for DC loads
DC direct current is different than AC alternating current.

AC current is a wave that crosses zero volts each time generator rotates 50-60 times per second,. US 60 cycles. Europe Asia 50 cycles.
DC current is a straight line. The voltage does not oscillate or vary like AC. Electrons flow through circuit at same voltage at all times.

When high voltage AC is turned off, the voltage drops to zero frequently.
When AC voltage hits zero, then the arc or spark or heat is easy to extinguish.
Result: AC switchgear like contactors last million repetitions without melting the points
High voltage DC is different. When high voltage DC is turned off, the electrons keep pushing. Voltage never reaches zero.
Result: DC voltage causes arc or spark or heat that is difficult to stop. Basically the electrons keep piling into the contactor.
DC switchgear must be rated for DC voltages, and be capable of extinguishing DC arc.
Illustration shows one method of extinguishing DC arc using 3-pole contactor. The circuit has 3 parallel switches on the positive wire.
With a 4-pole contactor, 3 poles can be used to turn off Positive, and 1 pole to turn off Negative
Add resistor in parallel with inductive winding* helps eliminate arcs. *Inductive winding is motor load

Buy:
3-pole contactors at Amazon
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 contactors 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.... salesman 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 electrical repairs

Resource:
Basic house wiring

Non-contact voltage tester

Test for power without touching connectors
NEVER assume power is OFF
Buy:
Non-contact voltage tester Amazon
Electric testers at Amazon
Resource:
How to test electric power is off
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 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

Buy:
Blue for 16-14 wire
Yellow for 12-10 wire

Resource:
How to install terminals
Treminals

Terminals

Buy:
Terminal kit
Blue for 16-14 wire
Yellow for 12-10 wire
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
remove cable staple
Buy
End cutting nippers at Amazon

 
linesman pliers
When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances on wire and creates weak point.
Buy tools:
Wire strippers at Amazon
Linesman pliers
Utility knife at Amazon
End cutting nippers at Amazon

Use solid copper wire
Fire inside timer caused by stranded wire
Keep enclosure door closed at all times
Buy:
soldering guns
Resource

Timer caught fire
Support the economy:
Buy water heaters from my associate links:

50 gallon Gas water heaters at Amazon
40 gallon gas water heaters at Amazon
50 gallon Electric water heaters at Amazon
40 gallon electric water heaters at Amazon
Hybrid / heat pump/ water heaters at Amazon

Resources:
How to install gas water heater
How to install electric water heater
Troubleshoot gas water heater
Troubleshoot electric water heater
Point of use water heaters
Resources:
Troubleshoot Gas valves with manuals
Icon gas valve

How to replace water heater element Waste King disposal
How to wire tankless electric

How to install tankless recirculation


Install point of use water heater
Titan tankless

Contactors/ relays
Install and troubleshoot garbage disposal Waste King disposal
Programmable timers

Woods timers
surge protection
Anode rods anode rods
Recirculation system

Tankless recirculation
Point of use water heater
Type 1 and type 2 surge protection surge protection
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Electronic parts

Industrial supplies

Tools and home improvement

Home and garden

Hayward pool
Pentair pool

Southwire electric
Buy
Tools

DEWALT
Black and Decker
Stanley
SKIL
Makita
Porter-Cable
Bosch

Irwin Hand tools
Klein hand tools
Fluke electrical testing
Dremel hobby tools

Campbell Hausfeld air powered
Tekton automotive

Powerbuilt automotive
Saws and saw blades
box timers Resource:
Compare box timers
DPDT timers
Intermatic
Control water heater w/ Z-wave
Intermatic control centers Resource:
Intermatic control centers: and parts
Digital control centers and parts
Tork control centers and parts
Subpanels
All control centers and parts
Enclosures
programmable timer Resource:
Programmable timers
Countdown timers
Off delay timers
On delay timers
Timer modules
Din rail
Twin & one-shot
Woods
Intermatic
Tork
Low voltage power packs Recirculation systems
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