CATCH Control 2CH Installation Manual

Introduction

CATCH Control hardware is used as a substitute consumption meter for compatible inverters and includes a range of additional features including inverter, battery and load control via our advanced hardware and software.

Our hardware and software can be connected and used in a variety of ways, so it is vital that you understand these instructions.

Please read these important details before commissioning:

• CATCH Control must only be installed by licensed electricians
• This manual is specific to the 2 Channel CATCH Control and must be read in conjunction with brand specific inverter installation guides.
• Ensure you follow the commissioning steps described in the correct order
• CATCH Control can be used to manage and control multiple inverter brands on a single site.  Please refer to each brand specific guide.
• CATCH Control CT’s must measure inverter production and site consumption for full functionality in most Modbus 485 RTU applications.
• In some Modbus TCP/Sunspec applications,  solar production measurement is not required.
• Multiple CATCH Controls/inverters can be connected via WiFi Cloud Tethering where required.
• In Modbus TCP/Sunspec applications, all CATCH Control hardware must be connected to the same local network
• CT’s can be extended up to a maximum of 10M and will require a 120 Ohm terminating resistor in such applications.
• All CATCH Control hardware must be WiFi connected to enable full functionality, support and warranty and Bluetooth connected for commissioning

Before Getting to Site

You will need the CATCH Configurator app and CATCH Monocle apps installed and registered to commission our hardware.

To register, modify or troubleshoot the CATCH Configurator or CATCH Monocle app refer to this guide.

1. Installing the hardware

Hardware installation is broken down into the following steps:

• Power and CT connection - Connecting CATCH Control wiring
• Inverter Connection – Connecting an inverter
• Load Connection– Connecting a load

1.1 Power and CT connection

Install the CATCH Control and connect the Power and CT’s as shown in the diagram below.

• Only use compatible CT’s supplied by CATCH Power
• The CT’s should ALWAYS be placed on the active wire, never the neutral.
• Always terminate the CT into the device BEFORE clamping it around the wire
• Make sure the arrow on your CT is pointing in the same direction as the arrows in the circuit diagram
• The white CT wires go into the W1 (channel 1) and W2 (channel 2) connections at the top of the hardware. The black wires share the same BLK connection at the top of the hardware
• ALWAYS connect the Mains CT to W1  and the Solar CT to W2
• Connect  active and neutral power to the power port on the bottom of the CATCH Control via a suitably rated RCBO

NOTE : If your main consumption meter is remote from the inverter, you can install multiple CATCH Control devices and wirelessly connect them to enable full wireless control via our “Cloud Tethering” feature. Refer to our Cloud Tethering guide here.

1.2 Inverter connection

The majority of inverters CATCH Power controls are connected via hardwired RS485 RTU cable. The following diagram shows the generic 485 connection.

• Use CAT6 or equivalent cable. The voltage rating needs to be 600V or better as it is being run through the switchboard.
• Use a twisted pair as the A and B conductors (ie Blue and Blue Stripe)
• Keep the cable away from large current carrying conductors if possible.
• For runs longer than 10m terminate the Solar Relay end with the 200 Ohm resistor supplied in the box.
• If you are controlling multiple inverters on the same site you will (generally) need multiple CATCH Controls communicating via RS485 to each inverter, and will need to commision and set up each inverter separately.

Please refer to the individual Inverter Guide for unique connections for each brand which can and do differ.

Please also note that SMA, Fronius and Fimer inverters can be connected via RS485 TCP which does not require a hardware RTU connection.

When terminating with the resistor follow the technique below.

1.3 Load Connection

CATCH Power’s 2CH hardware includes the ability to drive an optional AC contactor to turn loads on or off. The following diagram shows the generic connection.

• NEVER attempt to drive a load directly from CATCH Control hardware
• Choose a suitably (load) rated 230V AC Contactor which is Normally closed. We recommend Contactors with a bypass switch.
• You can use more than one Contactor but can only set one schedule (ie they will behave the same)
• Connect either of the Active Out terminals from the CATCH Control to either A1 or A2 on the contactor, and connect the Neutral to the neutral terminals.

2. Initial commissioning

3. Apply power to the CATCH Control.

4. When power is applied the Power and Bluetooth LEDs will flash on and off for about 20sec, then just the power light will stay on.

5. Open the Configurator app and connect via Bluetooth. Using the Wizard, follow these steps (or Watch the video here):

   1. Introduction and start up -  initialisation of commissioning
   2. Connect -  select the serial number of the device and connect
   3. Firmware update - ensure the latest firmware is installed and update
   4. Connect to WiFi - enter local wifi credentials and ensure wifi signal is a minimum of -60db
   5. Attach to site - create a site for the owner or search for existing site and attache device
   6. Inverter control - select the inverter brand and type. Refer to the relevant inverter commissioning guide for unique modbus settings.
   7. Channel set up - ensure CT and channels are connected and reading correctly. Name CT channels here.
   8. EDDE Control - enable EDDE control if you require inverter or battery control, backstop, flexible or static export management, EV or wholesale market control
   9. Export Control - Static, Dynamic and Backstop limits are set here. Begin by setting the inverter export limit to zero in the native inverter app and then, choose the appropriate export control method in EDDE  (Backstop operates under the Dynamic mode). Press save. when complete.
      1. Enter the sites NMI number. If correct, the DNSP Identifier will be displayed.
      2. Enter the total solar size in Watts (defined as maximum inverter rating)
      3. Press save. You should see 4 green ticks in the status page indicating correct registration
   10. Save configuration - save your settings

3. Testing the installation

Once installed, powered up and updated check the readings are correct in Live Data found in the main menu.

The CATCH convention for power is as follows:

A POSITIVE power number is power being consumed (or imported) on the premises.
A NEGATIVE power number is power being produced (or exported) from the premises.

Keep your eye on the voltage measurement. If you don’t see it changing the live data screen may have stopped refreshing. It does this to conserve phone battery. To make it start refreshing again use the menu on the top left to navigate to a different screen, then come back to the Live Data page.

3.1 Test the Mains CT

This test allows you to conform the solar CT is reading correctly. Shutdown the solar and use your tong meter to measure a minimum of 2A on the Mains circuit.

• The current should match what you are seeing on your tong meter
• Power measurement should be Positive
• Power factor should be >0.7

3.2 Test the Solar CT.

This test allows you to conform the solar CT is reading correctly.Turn on the solar system and use your tong meter to measure a minimum of 2A on the Solar circuit.

• The current should match what you are seeing on your tong meter
• Power measurement should  be Negative
• Power factor should be >0.7

3.3 Test the RS485 RTU connection

This test allows you to confirm that the inverter and CATCH Control meter are communicating correctly.

• Make sure your inverter is on and configured for an energy meter
• Navigate to the Live data screen on the Configurator and select the RS485 section.
• Ensure Signal Found shows a connected 48 signal (indicated by “1”)
• Ensure Locked On shows a stable connection (indicated by “1”)
• Ensure Rcv Message Count is steadily growing as data flows (will steadily increase)

3.4 Testing the Load Contactor

• Navigate to Device Settings in the Main menu
• Expand System Override 1 and configure it as follows :
  • Active Override YES
  • Override Type TURN ON
  • Start time 6.00am
  • Stop time 6.00pm
• Hit the Save  button

The Solar Relay Load On light should have turned on. If the Load On light didn’t turn on check the settings you used in Override 1.

• Make sure the time period suits your current time, and make sure you choose TURN ON.
• You should hear the contactor go “CLUNK”, and the contactor indicator light should be on.

If you didn’t get this, then check the following:

• Make sure the Active Out from the Relay is connected to either A1 OR A2 on the contactor
• Make sure that Neutral is connected to the other A1, A2 terminal (the one that Active Out is not connected to).
• Check to make sure an RCD has not tripped. If an RCD has tripped check to make sure your neutrals are as they should be. Remember the most common cause of an RCD tripping will be neutral return currents not passing through the RCD.
• Tong the load wire passing through the contactor, and make sure there is power flowing to the load.

Once you have confirmed correct operation, go back to System Override 1 and change them back to the defaults. You will set up custom Load Control settings at a later step.

3.4 Testing set up in the Monocle

The final testing step is to check the site looks correct in the Monocle app.

As part of the site creation process, an email with instructions has been created and sent to the customer. The customer will receive an access token required to register themselves as the owner of the site you have created.

• Open the Monocle app and log in
• If this is your very first Monocle site, the site should open as the default site. If you have multiple sites already, choose the site from the Site List by entering the address
• Check that the production and consumption numbers appear correct
• If a load contactor is connected, test the function using the load control on/off icon
• If the site is participating in a Dynamic or Backstop exports program then “Derick the Dynamic Gateway” control icon should be present, letting you know the current site export limit

If all displays are correct, the site is correctly configured.

4.0 Setting up the Load controller

Use the Configurator to set up the CATCH Control to drive the contactor based on schedules or events. By default the device is setup to a common configuration used for controlling hot water loads in Queensland. Have a look at the settings and see if they suite your specific circumstance, if not then change them.

You can program and combine up to 4 different modes of operation, with each configuration active for a particular period in a 24hr window.

• Navigate to Device Settings from the main menu
• Choose the appropriate control mode to suit the owner needs:
  • **Export Control :**turning on and off based on solar export levels. Good for Solar self consumption
  • Voltage Control : turning on and off based on voltage levels. Good for trying to reduce voltage rise issues
  • **Frequency Control :**turning on and off based on frequency. Good for use in a microgrid environment.
  • Turn On/Off: Manual control of the contactor
  • Top up: this one is a little tricky. Top up mode ensures a minimum amount of energy delivered to the load every 24hrs. Excellent for ensuring nobody runs out of
    hot water.

4.1 Example load control set up

The following example describes a typical Hot Water Load control setup, using two overrides operating together.

• Override 1 - Capturing exported production to trigger a hot water element and setting the element size
• Override 2 - Triggering a Top Up if the amount of energy delivered in Override 1 was not delivered

The goal of this configuration is firstly to turn on a 3.6kW element when >3.6kW of excess production is being exported, and turn off the contactor if <3.6kW is delivered for >5minutes. Override 1 defines the hours to look for excess (7am to 5pm), the element/excess size (3.6kW) and the time to shut off in excess power is not available (5minutes).

 Secondly,  we want a minimum of 4hrs of energy delivered to the load to ensure adequate heating. If the amount of energy delivered during the day is less than the 4 hours we have defined, the CATCH Control will make up the difference by turning the load on
at 10pm. If the amount of energy already delivered is greater than or equal to the 4 hours, nothing will happen at 10pm. The number of hours defined in Override 2 establishes this (between 10pm and 2am).

The hot water element will automatically turn off when it reaches normal temperature cut off thresholds.

Override 1

Override 2

5. Completion and support

The configuration and Monocle apps should now be operating correctly and the site is ready for use.

• The Commissioner Wizard will notify you if things look abnormal.

• Ensure you provide the Owners Guide to system owners so they understand how to adjust the site settings if required

• Ensure you provide a link to the Wifi reconnection guide so owners can reconnect if wifi drops out.

• To configure unique settings for load control, EVSE control or market price control please refer to our detailed service specific guides.

• WiFi connection guide

• Owners Video Guide to the Monocle

• Owners written guide to the Monocle

• Market pricing guide

Support

Please contact our tech support team on (02) 5700 5717 for assistance on set-up or commissioning.

CATCH Power

180 Dumaresq Street Glen Innes NSW 2370 Australia

Ph: +64 2 5700 5717

www.catchpower.com.au

sales@catchpower.com.au