Catch Power SOLAR RELAY Operation manual
IMPORTANT
This product must be installed by a
licensed electrician. This product must be
installed according to the AS/NZ3000 –
Australian Wiring Standards.
DANGER
Danger to life due to high voltage AC
Always ensure all electricity sources are
appropriately isolated when installing this
piece of equipment.
CATCH Power SOLAR RELAY –Installation Manual - Page 2
DANGER
Electric Shock Risk with CT’s
CT’s must be fitted to insulated cables
only. Ensure CT is terminated into the
device before clamping onto cables.
Specifications
CATCH Power SOLAR RELAY –Installation Manual - Page 3
Operational Voltage 230VAC
Operational Frequency 50Hz
Maximum AC Load 4A
Load Types Any
Max A/C Cable Size 2.5mm2
CT lead length 1m
IP Rating IP2X
Operating Temperature range -20oC to +45oC
Size 35W x 85H x 65D (mm)
Standards Conformity IEC 60730-1, AS/NZS CISPR 32:2015
Inside the package
1 x CATCH Solar Relay
1 x Current Transformers
CATCH SOLAR RELAY Installation
CATCH Power SOLAR RELAY –Installation Manual - Page 4
CATCH Solar Relay has been designed specifically for the solar industry, as such the
terminal layouts are designed for maximum flexibility and simplicity of wiring.
Highlights on the installation are:
•DIN Mounted.
•Same size as a 2
Pole miniature
circuit breaker
Duplicated power
terminals for easy
daisy chaining.
•CATCH Solar Relay is the size of a 2 pole miniature circuit
break, it must be mounted inside an electrical enclosure
such as a switch board, sub board, load centre, or any
other enclosure designed to house electrical switch gear.
CATCH Solar relay is designed to be DIN mounted inside a
standard miniature circuit breaker cover.
•CATCH Solar Relay is designed to control loads via an
external contactor. This means the number and type of
loads controllable by CATCH Solar Relay is only limited by
your imagination.
CATCH Solar Relay can control one or more contactor coils
(up to a maximum load current of 4A). CATCH Solar Relay
will happily drive one or more single or 3 phase contactors.
•Power terminals are duplicated for easy daisy chaining to
other power control devices.
INSTALLATION - Overview
CATCH Power SOLAR RELAY –Installation Manual - Page 5
Before Going to Site:
•Download the CATCH Power Configuration App to your phone. The App can be
downloaded from Google Play Store or the Apple iStore.
Onsite Site:
•Install CATCH Solar Relay as per the circuit diagram below.
•Power the device up and connect to it using the CATCH Power Configuration App
on your phone or tablet. The Configuration App uses Bluetooth to communicate
with the CATCH Solar Relay.
•Adjust the device settings to suit the installation.
CATCH Power SOLAR RELAY –Installation Manual - Page 6
INSTALLATION –Circuit Diagram
Cable Sizes:
Maximum wire size for the Solar Relay is 2.5mm2.
Contactor:
Contactor selection should be made based on load requirements. The solar relay
requires the coil voltage to be 240VAC, with a maximum coil current of 4A.
Current Transformer:
If the export control feature of CATCH Solar Relay is required then the CT must be
installed. The CT can be positioned anywhere in the installation that sees all loads
and solar.
Type AC
10A RCDBO
CATCH Power SOLAR RELAY –Installation Manual - Page 7
INSTALLATION - Cable Termination
Ideal cable size 1.5mm2 Maximum cable size is
2.5mm2
There are 3 connections that need to be made on
the bottom of the CATCH Relay, each connection
can be made from one of two connection points.
For example: The Active IN connection point is
made from one of the left two connectors. You
can choose either one, as they are bussed
together inside the device.
Example:
Wiring for a basic installation. As you can see it
does not matter which of the two terminals you
choose for each connection.
Active In
Active Out
Neutral
CATCH Power SOLAR RELAY –Installation Manual - Page 8
•The arrows next to the CT’s in the wiring diagram represent the
arrows on the inside of the CT’s.
•Matching the CT’s to the correct phase is critically important
special care must be taken to ensure this happens.
•NEVER disconnect CT’s from the Solar Relay while they are
wrapped around a current carrying conductor.
•Multiple wires can be put through the CT, as long as all currents are
in the same direction and in phase.
IMPORTANT Current Transformer Rules
IMPORTANT
INSTALLATION –Current Transformer
CATCH Power SOLAR RELAY –Installation Manual - Page 9
IMPORTANT
It is vitally important the CT’s are
pointing in the right direction.
Mains
DANGER
Electric Shock Risk with CT’s
CT’s must be fitted to insulated cables
only. Ensure CT is terminated into the
device before clamping onto cables.
CATCH Power SOLAR RELAY –Installation Manual - Page 10
INSTALLATION –Current Transformer
Match the CT wire colours to the labels on the case.
Note there is a 1 terminal gap between the white and black wire.
Solar Relay Terminal CT wire colour
W white
BLK Black
CATCH Power SOLAR RELAY –Installation Manual - Page 11
INSTALLATION –Power Up
There are 3 LEDs on the Solar Relay that provide
indicators on what is happening.
Power: Green indicates power is applied to the
unit, and the unit is functional.
Load On: When green it means power has been
applied to the Active Out port.
Blue Tooth: When Blue it means the Solar Relay
is connected to a mobile device.
When power is applied to the unit all three lights
flash on and off together for 20 seconds, then
under normal conditions the Power light will
come on by itself.
At this point you can connect to the device via
the mobile application and begin the
configuration process.
IMPORTANT
The Factory default configuration has the
Solar Relay permanently turned off. You
must override the default configuration.
CATCH Power SOLAR RELAY –Installation Manual - Page 12
INSTALLATION –Configuration
CATCH Solar Relay is configured over a Bluetooth connection using the CATCH
Configurator App.
The CATCH Configurator app is available on the Apple App Store and Google Play.
Scanning for new Devices
When the Configurator opens it will
automatically start searching for any Catch
Power devices.
In the example shown to the left a single
device has been found. You can tap the
screen to end the search once the device is
found.
Device name format
4321-SR/CATCH
Device Serial Number
Device Model
CATCH Power SOLAR RELAY –Installation Manual - Page 13
INSTALLATION –Configuration
Once you have chosen the device, the Configurator App will connect. At this point
the Bluetooth light on the device will turn on and the Configurator App will show
you the Live Data View.
Understanding the Live Data
CATCH Solar Relay is monitoring all aspects of
the connected site. The data is visible on this
screen.
Device Time: The current time as reported by
the device. This is updated automatically
when the configuration is changed.
Volts: The RMS voltage as seen for the Relay.
Amps: RMS current as measured by the CT.
Freq: Grid Frequency
Power: The power measured at the point the
CT is connected. A negative number
represents exporting power flow.
Run time: The amount of minutes since
midnight the load has had a voltage applied.
Duty: Status of the connected load. 1 means
the load has a voltage applied. 0 means no
voltage is applied (the load is off).
CATCH Power SOLAR RELAY –Installation Manual - Page 14
INSTALLATION –Configuration
Once you are connected to the Solar Relay there are a number of menu options
you can choose from.
Understanding the menu
Find Devices: Will disconnect you from the
current device and perform another device
scan
Live Data: opens the Live Data screen.
Configuration: Opens the configuration
screen which allows you to adjust the device
settings.
Change Password: The device is shipped with
a blank password, which means you will not
be prompted for a password when you open
the configuration screen.
Firmware Update: Opens a screen that
allows you to update the latest firmware on
the device.
CATCH Power SOLAR RELAY –Installation Manual - Page 15
INSTALLATION –Configuration
CATCH Solar Relay is highly flexible and can operate in many modes. The details of
all configuration options are outlined below.
General Configuration
Date/Time: This is the time that will be
loaded into the device. It is based on the time
current held on the mobile device running
the Configuration App.
CT Ratio: If you are using the standard model
(CP-SR-STD) you will be using the supplied CT.
as such you do not need to change this
number.
The industrial version of the Relay uses
standard 5A secondary CT’s. You will need to
specify the applicable CT ratio. For example if
you are using 400A primary current CT’s the
CT ratio will be
CATCH Power SOLAR RELAY –Installation Manual - Page 16
INSTALLATION –Configuration –System Overrides
By default the solar relay sits idle, you must specify 1 or more overrides in order
to get the unit controlling the load.
•A maximum of four overrides can be configured.
•Each override has a start and stop time.
Each override represents a specific mode of operation. There are 6 operating
modes that can be chosen.
Export Control: In this mode the Solar Relay controls the load based on solar
export levels. This mode is ideal for maximising solar self consumption.
Turn On: In this mode the Solar Relay will turn the load on for the period of time
specified.
Turn Off: This mode forces the unit to turn off the load for the period of time
specified.
Top Up: In this mode the Solar Relay will ensure the load has been on for the
period of time specified. For Example if the Top-up mode is specified to be
between 10pm and 11:30pm (1.5hrs). It will turn the load on if we did not manage
to get 1.5hrs of running time to occur during the day.
This mode is typically used in conjunction with another mode like Export Control
and Voltage / Frequency Control. This mode guarantees a minimum amount of
running time in a 24hr period.
Voltage Controlled: In this mode the relay will turn the load on and off based on
Grid Voltage. This mode is best suited for helping to manage voltage rise issues at
a solar installation.
Frequency Controlled: In this mode the relay will turn the load on and off based
on grid frequency. This mode is ideal for operating in Off grid environments where
frequency shifting is used to control devices. Systems such as SMA use frequency
control in their off grid environments.
CATCH Power SOLAR RELAY –Installation Manual - Page 17
INSTALLATION –Configuration –System Overrides
Each System override has the following settings
Override Active: Valid values are Yes or No.
Any override with active status of No will be
ignored.
Override Type: This is where you define how
the Solar Relay will function for this override.
Start Time: When do you want the override
to start
Stop Time: When do you want the override
to finish.
Override Start and Stop times can overlap.
For example:
Override 1
7am 6pm
Override 2
11am 2pm
In this example override 1 will be used to control the load between 7am and
11am, then Override 2 will be used from 11am –2pm, then Override 1 will be
used between 2pm and 6pm.
CATCH Power SOLAR RELAY –Installation Manual - Page 18
INSTALLATION –Configuration –System Overrides
Override Stop time can be less than the Start time.
For example:
Override 1 : Starts at 11pm, and Stops at 6am
Override 1
6am
11pm
In this example Override 1 will start at 11pm tonight and continue until 6am the
next morning.
midnight
CATCH Power SOLAR RELAY –Installation Manual - Page 19
INSTALLATION –Configuration –Export Control
In order to configure the solar relay to use the Export Control mode follow these
steps.
Minimum On Time: Specifies the minimum
time the load must stay on once it has been
turned on.
Above Threshold: The number of watts to be
exporting from the measuring point. The
Solar Relay will turn the load on if exporting
reaches this threshold.
Above Time: The number of minutes the
Above Threshold needs to occur before the
load turns on.
Below Threshold: The number of watts to be
exporting from the measuring point. The
Solar Relay will turn the load off if exporting
goes below this threshold.
Below Time: The number of minutes the
Below Threshold needs to occur before the
load turns off
1) Setup one of the four system overrides to be Export Controlled.
2) Configure the Export Control parameters as described below.
Example:
A site has 6kw of solar, and wish
to turn a 1.5kW heat pump on
when the solar export is above
3kW for 5 minutes. The customer
does not want the load to be
powered from any imported
energy.
Settings:
Minimum on Time: 0
Above Threshold: 3000
Above Time: 5
Below Threshold: 0
Below Time: 0 You must always ensure the difference
between the Above and Below thresholds are
greater than your load size. For example if
you are powering a 3kW load the Above
Threshold must be 3kW bigger than the
Below Threshold otherwise contactor
oscillations will occur.
CATCH Power SOLAR RELAY –Installation Manual - Page 20
INSTALLATION –Configuration –Top-up Control
Top-up Control is typically configured in conjunction with another control mode.
When configuring Top-up control you are telling the Solar Relay how many total
minutes you want the load to run in a 24 period. If the run time of the load using
other control mechanisms did not reach this duration, the Top-up mode will
trigger and complete the running time.
In the example to the left you can see System
Override 1 is setup to be Export Control and
System Override 2 is our Top-up mode.
Between the hours of 7:00am and 7:00pm
the Solar relay will run in export control. The
number of minutes the load runs during this
time will change from day to day based on
the amount of exporting solar.
At 11pm the Solar Relay will start operating in
Top-up mode. The number of minutes
between the start and stop times on the Top-
up override represents the total number of
minutes we want the load to run for. In our
example there are 300 minutes between
11:00pm and 4:00am the next morning. This
tells the Solar Relay that we need a total of
300 running minutes for the entire day.
If we had a nice sunny day, and the total
number of run time minutes during the
Export Control mode was 300 minutes or
better, when we get to 11pm the Solar Relay
will not turn the load on.
If the day was not so great and the run time
minutes during Export Control mode was
only 200 minutes, when we get to 11pm the
Solar Relay will turn the load on and run it for
100 minutes.
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