Powerdiverter CTSA16-100A Operation manual

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Installation &
User Guide
For more information please contact CoverTel Power on 1800 (268 378)COVERTEL

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Installation Guide
Welcome to the Powerdiverter!
Thank you for purchasing this Powerdiverter. The Powerdiverter is the most flexible, cost-effective
solar energy manager on the market, designed to save you money on your fuel bills from the day
it’s installed.
Powerdiverter works with your solar PV system to store excess solar energy in the form of heat in
a hot water storage tank or storage heaters in your home (think of them as “heat batteries”!). By
storing your solar energy, rather than exporting it, Powerdiverter saves you money every day on
your electricity bills.
Here’s how it works. Your solar panels (1) generate electricity which is converted to standard 240V
AC mains energy by the solar inverter (2). This energy is measured by your solar and supply meter
(3). If no appliances are turned on in the home to consume the energy, it gets exported out to the
grid (7). But with the addition of the Powerdiverter Sensor (4) and a Powerdiverter Controller (5), the
excess solar energy can be diverted from going out to the grid and instead stored in your hot water
tank (6) during the day for use later. Simple!
Originally launched in the UK, this new Powerdiverter has been re-designed for Australia and
New Zealand with full support for higher power water heaters up to 4.8kW and higher ambient
temperatures than we see in the UK.
The Powerdiverter offers ease and flexibility of installation. With the wireless solar power sensor
unit you can fit the Powerdiverter indoors or outdoors without drilling through walls.
With the wired sensor input on the controller, you have the option
to connect the sensor directly.
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6
7
5 3
Figure 1
How the Powerdiverter works
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2

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Economy and convenience. The Powerdiverter has a special input for sensing when your controlled
load power circuit is activated by the electricity supplier for cheap rate electricity. The Powerdiverter
will then heat your water using the cheap rate electricity in addition to solar power so that you
always have hot water when you want it and at the lowest cost.
Hot water – your way! Program your own heating schedules with the 7 day 24 hour digital boost
timer to provide hot water at any time, day or night.
Need a quick boost? No worries! The boost button on the Powerdiverter gives you a quick 1, 2 or
3 hour heating boost without having to program the timer.
What’s in the box?
1 x Powerdiverter Controller unit.
1 x Powerdiverter Sensor unit (for wireless remote sensor installations only).
1 x Powerdiverter Sensor unit AC adapter.
1 x Sensor clamp with 5m cable.
1 x Wall plugs and screws kit
1 x Controller mounting template
1 x Powerdiverter installation and User Guide

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Safety Instructions
• If using the wireless sensor unit, use only the supplied Powerdiverter AC power adaptor or 2
x 1.5V C cells.
• Use only the provided Powerdiverter Split Core CT CTSA16-100A 100A/50mA clamp.
• Please follow the installation and usage instructions carefully. If the equipment is used in a
manner not specified by the manufacturer, the protection provided by the equipment may be
impraired.
• Please note that a qualified electrician must install this product.
When fitting the current sensor clamp, follow the fitting instructions and
check the safety of the electrical cables being handled. Parts of the electrical
installation may have exposed live terminals. Consult a qualified electrician if in
doubt before installing the sensor clamp.
Do not apply the current sensor clamp around or remove from hazardous live
conductors. The sensor clamp must only be fitted to insulated cables.
Switch off the circuit before commencing installation to avoid the risk of electric
shock.
The Powerdiverter has been tested and registered on the RCM product
database.
European Conformity is a conformity marking for products sold in the European
Economic Area.
Waste Electrical and Electronic Equipment Directive is a European Community
directive that requires you to take any waste electrical and electronic equipment
to your nearest recycling facility.
Indoor use only. Unit should be installed in a location protected from weather
and moisture. See the Powerdiverter website for your stockist for more
information about suitalbe weatherproof enclosures.

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CABLES ONLY!
INSULATED
TO BE USED WITH
CAT II
(Indelible)
Bottom Label
(Indelible)
Cable Side Label
100A/50mA
CTSA16-100A
Split Core CT
Powerdiverter

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How to install the Powerdiverter:
To start off you will need to run through a quick checklist to ensure your home is suitable for the
installation. Please check the following:
• Do you have a grid connected solar PV system of at least 1.5kW output power?
• Is the solar inverter output connected to the same phase as the normal supply at the switch
box?
• Do you have a hot water tank with a working water heater fitted to it?
• Is your water heater rated at or below 4800W and 240V AC
• Does the water heater have a working thermostat?
• Is the water heater connected to an existing switched spur circuit? No other appliances
should be connected to it.
If the answer is yes to the all the above then you are ready to go!
Identifying Your Type of Electrical Installation
A variety of installation types exist. Please take a moment to look at the house wiring and select
the closest matching installation type. If in doubt, please contact Powerdiverter support for more
information.
There are two basic types of electrical installation:
Single Phase Supply
This is where the house has a single Active line supply of power that everything is connected
to. The solar inverter, house loads and the water heater all are fed from one Active line into the
property.
This is the easiest type of installation for the Powerdiverter to work with as the Powerdiverter
measures the net import/export power on the Active line where it leaves the property and controls
the water heater in the house fed from the same Active line. The other house loads can all share the
solar power as well.
The remainder of the installation instructions cover this type of installation.
Multi-Phase Supply
This is where the house has two or three Active line supplies.
One will be used for house loads (sockets and lights). The others will be used possibly for the water
heater, the solar inverter and/or other heavy loads (such as air conditioning or a pool heater). There
can be many variations on what is connected where in these types of installations, far too many to
cover in this guide.
The important thing to note is that the Powerdiverter Controller unit controls the active line to the
water heater and this must be on the same Active line phase as the solar inverter. The sensor
clamp (whether used directly with the Powerdiverter Controller or the wireless Sensor Unit) must
measure the net sum power of the solar generation trying to be exported to the grid, less the load
of the water heater trying to be imported from the grid ON THE SAME PHASE.

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If the water heater is connected to a different phase to that used for the solar inverter, the
Powerdiverter will not work. You will need to move the wiring for the water heater to be on the
same phase as the solar inverter before installing the Powerdiverter.
You may wish to do this permanently by altering the house wiring to the hot water system or it can
be achieved with a Powerdiverter Controlled Load Contactor to allow both power sources to be
used.
This is useful in situations where the water heater is installed on a dedicated Controlled Load phase
for off-peak cheap electricity to heat the water. In this case, the water heater wiring is modified so
that when the Controlled Load power is turned on (by a utility meter with a dedicated Controlled
Load output or separate utility provided Load Control Unit), the Powerdiverter Controlled Load
Contactor automatically connects the water heater to that power line. When not activated, the
contactor automatically connects the water heater to the Powerdiverter Controller unit and feeds it
solar power.
See the section of the installation guide on Controlled Loads for more information or contact
Powerdiverter support for advice.

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Step 2: Check the existing wiring between the water heater spur switch and the inside of the water
heater cap. If the wire is not 2.5mm² high temperature water heater cable, replace it. If any cable
insulation is burned or damaged in any way, replace the cable. If in ANY doubt about the safety of
the cable – replace it!
Make absolutely certain that the water heater element is working and the thermostat and the
secondary anti-boil cut out are in good condition and safe. If the water heater does not have a
secondary anti-boil cut-out, replace the thermostat with a new one that does.
Test the heating circuit with a meter that reads DC Ohms resistance and check that the heating
element reads 12 Ohms or more (for a 4.8kW, 240V AC heater element) across the Active and
Neutral terminals where the cable from the Powerdiverter connects. If it reads lower than 11.5
Ohms, check the power rating of the heating element and check the wiring for short circuits. If
it reads more than 25 Ohms, check the heating element, thermostat and secondary cut-out (if
present).
Tip: If you do not have a test meter, a quick check is provided by the Powerdiverter LEDs. When
the heating circuit is being fed power but the circuit is open, the ‘Knight Rider’ display shows on
the red LEDs. This normally means the water is hot but could mean the thermostat or heater or
wiring is faulty if the water is cold.
Step 1: Ensure the power has been isolated to the water heater feed circuit at the consumer unit
(and/or turn off the water heater spur switch).
Figure 2
Wiring the Powerdiverter

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Figure 3
Checking existing wiring
Figure 3 shows a classic example of burned out wiring from a faulty thermostat on an old water
heater. In this case the wiring and the thermostat had to be replaced before fitting the Powerdiverter.
Step 3: Open the Powerdiverter controller unit to see the connections. Install the supplied cable
glands into the pre-cut holes. If the existing cabling is long enough to reach into the Powerdiverter
and back out to the heater and is in good condition, you can simply cut the cable between the spur
switch and the immersion heater and re-use it in step 5.
Step 4: The unit should always be sited out of direct sunshine or places that are likely to reach
more than 40 degrees Celsius to avoid the unit becoming too warm and reducing its output power.
If installed outdoors, the unit should be installed in a weatherproof enclosure with ventilation to
allow cooling air to circulate around the Powerdiverter.
The unit should ALWAYS be installed in a vertical position
to allow cooling air to circulate from the bottom to the top
vents on the Powerdiverter enclosure.
Please ensure there is at least 10cm of clear space from
the top and bottom and 5cm of clear space to each side of
the Powerdiverter control unit for air circulation.
If the unit is installed in an airing cupboard do not cover the
unit with anything or allow items of clothing to block the air
vents as the unit may become too warm and shut down to
protect itself.
Fit the controller unit to the wall using the four screw holes
provided in the enclosure corners. Use the wall plugs and
screws provided or ones suitable to the type of wall. Check
for cables and pipes in the wall before drilling or screwing
into the wall!
A cardboard drilling template has been provided to make
this easier.
KEY BENEFITS:
HOT WATER FROM SOLAR PV
Powerdiverter has dual inputs allowing you to connect your on/o-peak
tari supplies ensuring hot water security at the lowest possible rates.
The powerdiverter uses custom-designed wireless technology to make this product the
easiest to install in Australia. Years of experience within the solar PV industry has been key to
the design and functionality of the powerdiverter to maximise your return on investment.
Built for Australia
Save up to $650 extra on
your annual energy bills
24/7 timer for scheduled hot
water boosting or use the
Easy Boost button for hot
water on demand
Powerdiverter automatically
knows when to boost to
protect against legionella.
Can be installed within
minutes with the wireless
battery or mains sensor unit
Extendable 5 year warranty
Variable power control that
delivers spare energy in all
weather conditions
No plumbing or additional
wiring required
Use up to 100% of the excess
power being generated
Hot water from your excess
solar electricity using your
existing hot water heater.
Compatible with all
hot water elements
up to 4.8kW
www.powerdiverter.com.au
[phone]
[e-mail]
5cm
10cm
5cm
10cm
5cm 5cm
10cm 10cm
Figure 4
Installation locations and position

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Step 5: Connect the power cable from the spur switch to the AC input connector on the left hand
side of the circuit board, following the Live (Active), Neutral and Earth markings. Solid core or
stranded cables up to 6mm² can be used. To open the connector, lift up the white levers. Strip 1cm
of insulation from the wires, twist the strands together and insert the bare wire end into the hole.
Flip down the lever.
Figure 6
Economy Sense
Step 6: Connect the water heater cable to the middle connector block on the circuit board in the
same way as in step 5 above.
Economy Sensor Connector
If required, connect a feed from the controlled load circuit to the right hand connector block.
Figure 5
Before wiring and after wired
Please consult your energy supplier to determine if your “normal” supply is also charged at a lower
rate during these times as this depends on the type of supply meter(s) fitted at your property.
This optional connection is for sensing the presence of power on the economy / cheap rate circuits
controlled by the electricity supplier.