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DC safety switches |
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Non-fusible DC safety switch 250 Volt DC safety switch outdoor Buy: $135 3-pole / outdoor/ 30 amp DC/ non-fuse 30 amp DC 240 volt outdoor Grounding lugs at Amazon< |
| Difference between AC and DC safety switch wiring |  |
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fusible DC safety switch 250 Volt DC safety switch indoor Buy: $335 3-pole / outdoor/ 30 amp DC/ fusable |
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30
amp DC safety switch/ fusible/ outdoor Heavy Duty 250 V Dc Voltage; 30 Ampere Use 10 gauge wire Do not use fuses larger than amp rating of wire Buy: Square D 30 amp DC HU361RB 30 amp DC 240 volt 600 Volt Resource: Generic: How to wire safety switch Convert AC water heater to DC water heater DC relays for solar power DC safety switch wiring/ pdf Schneider safety switch wiring for DC/ pdf Schneider safety switches/ pdf |
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60
amp DC safety switch/ fusible/ outdoor Heavy Duty 250 V Dc Voltage; 60 Ampere Use 10 gauge wire with 30 amp fuse Use 6 gauge wire with 60 amp fuse Buy: Square D 60 amp DC H222AWK Resource: Generic: How to wire safety switch Convert AC water heater to DC water heater DC relays for solar power DC safety switch wiring/ pdf Schneider safety switch wiring for DC/ pdf Schneider safety switches/ pdf |
 600 volt AC @ 30 amp fuse/ 300 volt DC @ 15 amp 600 volt AC @ 600 amp/ 120 volt DC @ 60 amp 6000 volt AC @ 6000 amp/ 300 volt DC 2000 amp Time delay fuse passes surge currents without sacrifice short circuit limitation AC rating for 200 kA is reduced to 20 kA for DC kA is max surge capability... if too much surge is on the fuse, the fuse will not trip and fuse can melt onto the contacts, feeding high voltage into the wire causing possible fire  |
Bussman Buy 60 amp DC cartridge fuse 50 amp DC cartridge fuse 40 amp DC cartridge fuse 35 amp DC cartridge fuse 30 amp DC cartridge fuse 25 amp DC cartridge fuse 20 amp DC cartridge fuse 70 amp DC cartridge fuse 90 amp DC cartridge fuse 80 amp DC cartridge fuse 125 amp DC cartridge fuse 150 amp DC cartridge fuse 175 amp DC cartridge fuse 200 amp DC cartridge fuse 225 amp DC cartridge fuse 250 amp DC cartridge fuse 300 amp DC cartridge fuse 350 amp DC cartridge fuse 600 amp DC cartridge fuse Buy Class R fuses at Amazon 30 amp Cartridge fuse 60 amp Cartridge fuse Busman fuses at Amazon Resource: Busman fuses/ pdf |
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Example
DC safety switch for solar array
Use fused or non-fused This is one way to use safety switch Purpose of safety switch is to ensure all power is OFF The handle is clearly visible and can be latched in place Locate safety switch in plain sight so people can clearly identity when power is OFF Remember, a solar panel will produce electricity each time it is exposed to light. You can get shock from solar panel when panel is exposed to sun. The array and safety switch must be wired at night The strings can be combined before connecting to safety switch... match total volts and amps with safety switch rating and with fuse rating When three panels are wired together, the positive wire connects to negative wire to make a string. Solar panels are like batteries. When three panels are connected in series, or in a string, then voltage increases with each additional panel, but amperage stays the same. Illustration shows 3 strings with 3 panels in each string. If the strings are combined together in parallel, then the voltage stays the same but amperage increases. Maximum voltage for wire and safety switch is 600 volts AC/ 300 volt DC Resources: Calculate volts and amps for array/ How to set up array DC safety switch wiring/ pdf |
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100
amp Non-fusible/ outdoor 250 VDC 30 amp Buy: 100 amp non-fusible/ outdoor/ at Amazon Resource: Generic: How to wire safety switch Convert AC water heater to DC water heater DC relays for solar power |
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  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 DC relays for solar power |
| DC arc extinction/ controlling
high voltage DC "the higher the number of contacts opening the circuit, the higher the breaking capacity of the circuit-breaker. This means that, when the voltage rises, it is necessary to increase the number of current interruptions in series, so that a rise in the arc voltage is obtained and consequently a number of poles for breaking operation suitable to the fault level." What this quote means: A DC circuit breaker or any DC switchgear must have multiple contacts that disconnect as illustrated in diagrams below You want to increase the number of contact points, so the arc from DC power can be extinguished AC electricity oscillates. The voltage rises and falls. 60 times each second, the voltages drops to zero. Of course you notice this when grabbing a hot wire, because there is voltage on the line. There is a difference when choosing switchgear. Each time a switch is thrown, there is an arc (or spark) that continues to jump between the contact points of the switch. With AC power, the arc is 'extinguished' more easily because voltage reaches zero at some point and the arc stops. With DC power, the arc is more difficult to extinguish. DC never reaches zero volts, because it doesn't change direction... it doesn't oscillate.... and so electrons keep piling against one another, forcing the front ones to jump across the switch contacts. So switchgear must be rated for DC. Using AC switchgear will sometimes work, BUT careful attention must be paid to rating label. Each switch has a rating label or rating specifications. For example a switch might be rated 240 volt 30 amp AC, but only rated 48 volt 3 amp DC. If a device does not show DC rating, then assume it is not sufficient for DC application, and might be fire hazard. "the higher is the number of contacts opening the circuit, the higher is the breaking capacity of the circuit-breaker. This means that, when the voltage rises, it is necessary to increase the number of current interruptions in series, so that a rise in the arc voltage is obtained and consequently a number of poles for breaking operation suitable to the fault level." So a DC circuit breaker or any DC switchgear must have multiple contacts that disconnect as illustrated in diagram below. Resource: DC arc extinction .pdf Read about difference between AC and DC |
 3-pole
contactor wired for DC
loadsThe higher the number of contacts opening the circuit, the higher the breaking capacity DC direct current is different than AC alternating current. Illustration shows one method of extinguishing DC arc using 3-pole contactor. The circuit has 3 parallel switches on the positive wire, thus helping to stop the arc better than 1 switch. If a 4-pole contactor is used, 3 poles can be used to turn off Positive, and 1 pole to turn off Negative. To help eliminate arcs, add a resistor in parallel with inductive winding. Example of inductive winding is motor load When high voltage DC is turned off, the electrons keep pushing because the voltage never reaches zero. Result: DC voltage causes arc or spark or heat that is difficult to stop. Basically the electrons keep piling up and pushing the arc across the points of the contactor. DC switchgear must be rated for DC voltages, and be capable of extinguishing DC arc. Buy: 3-pole contactors Resources: Solar contactor/ pdf DC relays for solar DC contactor wiring diagrams/ pdf What is 3-phase electricity Can AC circuit breaker be used for DC |
| Use only 600 volt wire. Lamp cord, extension cords are not rated 600 volt. Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional. 30 amp breaker use 10 gauge / 120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.  Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps. Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp 120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire. ... cannot be connected to 30-40 amp breaker. 1  Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps. Buy: 12-2 gauge/ 20 amp 12-3/ 20 amp NMB is house wiring UF is underground Rolls of stranded wire HOOK UP Wires |
White
14 gauge 15 amp 120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.  White/ #14 gauge wire, with ground ... 15 amp capacity. Safe maximum 12 amps. Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
| 50-60
amp breaker use 6 gauge / 240 volt 50 outlet can be installed on 50 amp breaker only  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / 240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only  Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire. Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire. Generally ... use same size as other wire in circuit Buy: 12 gauge copper ground wire Ground wire Green ground wire Ground pigtails Ground rods/ ground clamps at Amazon |
 Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock. Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Non-metallic flexible conduit Power whip Armored cable Southwire armored cable cutter Pull boxes |
 Electrical tools must be insulated. Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off. Buy: Electrician tools kits KLEIN TOOLS Tools kits IRWIN tools KNIPEX Telephone cable knife Low Voltage Mounting Bracket for Telephone |
Push-on wire connectors in place of twist-on connectorsBuy:Push on wire connectors Amazon Red 3P connector for 10-14 gauge wire Lever connectors for stranded wire at Amazon HOOK UP Wires |
 Protect wiring from damage Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. -Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
  Electrically insulated tools When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistance and heat on wire and creates possible weak point. Buy tools: KLEIN TOOLS Wire strippers at Amazon Electric Wire Stripping Machine Linesman pliers Utility knife at Amazon |
 Multimeters Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire. Buy: Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line |
 GFCI circuit breaker A GFCI circuit breaker will protect all boxes on circuit. Circuit must be grounded. Ground wire must be continuous and connected to each piece of equipment. White wire on circuit breaker must be connected to Neutral busbar inside the breaker panel. Buy GFCI circuit breakers |
Push down 1" wide Push down breaker Plug-in breaker Buy single-pole: Choose from 15 to 60 amp Eaton CL series Siemens 15-60 amp Single-pole tandem breaker Tandem breakers |
Push down 2" wide Push down breaker Plug-in breakers Buy double-pole: Choose from 15 to 125 amp Choose from 15 amp to 200 amp Eaton CL series circuit breaker Siemens circuit breaker Double pole GFCI |
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