GRIDFREE BACH KIT User manual

INSTALLATION MAUNAL
BACH KIT

2
While this manual seeks to be as comprehensive as possible, some
aspects are not covered due to the different requirements for each
installation. We recommend consulting the applicable standards for all
installations. These may include:
- AS/NZ 3000
- AS/NZ 4509
- AS/NZ 5033
- AS/NZ 5139
Any installation aspect involving voltages above ELV (120VDC) or
groundworks is prescribed electrical work and must be carried out by an
accredited electrician.
WARNING - READ CAREFULLY
Risk of Electrical Shock, Burning and Explosion
- Improper installation or failure to follow proper work-site practices can
place the installer and user at risk of multiple hazards.
- The installation contains works with multiple voltages that can cause
electrical shock.
- Improper installation can cause excessive electrical currents, which may
lead to burning.
- Lead-acid batteries can also release hydrogen gas when they are
charged, which can create a fire or explosion hazard if it accumulates in an
enclosed space.
Risk of Chemical Burn and Poisoning from Battery
Electrolyte
- Lead acid batteries contain sulfuric acid, which can cause burns and
other injuries if it comes into contact with skin or eyes.
- Risk of respiratory problems from inhaling battery acid fumes.
- Do not open or modify the battery.
- Use correct personal protection equipment, such as rubber gloves, boots
and goggles, when handling and installing batteries.
Risk of Injury due to Short Circuit Currents
If a battery bank’s output is short-circuited, injury due to heat or eye injury
due to arc flash may occur.
When working with the battery bank:
- Connect one wire at a time.
- Use battery caps.
- Use insulated tools.
- Do not wear any conductive items.
- Do not place any tools on the batteries.
Risk of Injury due to the Handling of Heavy Objects
- Components in the installation, such as batteries, are very heavy.
- Get help from a partner or team to lift and move heavy objects.
- Use proper lifting techniques and equipment such as dollies, carts and
forklifts.
- Improper handling may lead to back injuries, strains or sprains, slips, trips
or falls.

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BACH KIT
Installation of this kit does not require an electrician. However, we recommend
seeking help if you are not confident in your ability at any stage.
We are always happy to help guide you through the install, troubleshoot, and answer any
questions. You can contact us on 09 218 5533, or [e-mail].
We recommend reading these instructions in full prior to starting your install.
All wiring and voltages in this kit installation are well under the 120V DC standards for
extra-low voltage (ELV). ELV is an electricity supply voltage in a range which carries a very low
risk of electrical shock.

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KIT CONTENTS
x4
x4
1x 60A MPPT Charge Controller (6415AN)
4x PERC MONO Solar Panel
4x 12v200Ah Deep Cycle Gel Battery
1x IPT 3000W 48V Pure Sine Wave Inverter (IPT3000-42)

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1x 32A Solar PV DC Circuit
Breaker
The “C” label is the same as the Amp “A” label of the breaker.
1x 63A Charge Controller DC
Circuit Breaker
1x 125A Inverter DC
Circuit Breaker
1x HT-8 MCB Enclosure
1x 25mm² Cable 3m Pre-Crimped (Red + Black)
2x 25mm² M6 Crimps
1x 16mm² Cable 3m Pre-Crimped (Red + Black)
3x 50mm² 30cm Battery Link Cable
1x 6mm² Solar PV Cable Pair 10m – Pre-Crimped MC4
(Red + Black)
1x MC4 Y-Branch Connector Cable Pair 2.5m
2x PV Inline Fuse
x3
x2
x2

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REQUIRED TOOLS
Screwdrivers
Wire Cutters
Drill Wire Strippers
25mm Lug Crimping Tool 6mm Allen Key
13mm Spanner Socket Set
SOLAR MOUNT OPTIONS
Ground Corrugated L-FeetTilt

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WIRING OVERVIEW
11
11
33
33
22
22
63A Charge Controller DC Circuit Breaker
32A Solar PV DC Circuit Breaker
125A Inverter DC Circuit Breaker

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SOLAR PANEL WIRING
1
1Start by creating two pairs of panels wired together. Connect the positive terminal of one
panel to the inline fuse, then to the negative terminal of the next panel.
PV Inline Fuse

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2Connect the Y-branch connectors to one of the solar panel pairs.
Y-branch
connectors

Solar Panel Wiring
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3Connect the other pair of solar panels to the Y-branch connectors, connecting the
negative terminals from each pair with the black Y-branch connector, and the positive
terminals from each pair with the red.
This creates two outputs from the solar array: one positive (+), one negative (-).

Solar Panel Wiring
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
DO NOT connect the
cable run to the solar
panels until all solar
wiring is complete.
Run the solar cables to
the C32 circuit breakers,
and cut it to length.
The PV cable must be run inside of a suitable conduit when the cable is run across a roof,
floor, or the interior of a building.
DO NOT connect the cable run to the solar panels as the
cables will become live. Wait until all solar wiring is complete
Run the 6mm2PV solar cables from the solar panels back to the C32 circuit breakers, and
cuit it to length.
4

Solar Panel Wiring
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C32
Indicator is green, showing the
circuit breakers are switched off
Ensure the solar cable run is NOT connected to the solar panels, and
the circuit breakers are switched off (green indicator, switch down)
Use wire strippers to strip the ends of the solar cable, and terminate them in the circuit
breaker by inserting the stripped end and tightening the screw clockwise. Make sure
the clamp inside the circuit breaker is in contact with the metal conductor, and NOT the
insulation of the wire.
5

Solar Panel Wiring
13
Connect the cable run
to the solar panels
Ensure the circuit
breaker is switched off
When the cables have been terminated in the circuit breaker and the circuit breaker is
switched off, you can now connect the solar panels to the cable run. The circuit breaker
must be switched off when connecting or disconnecting the solar panels from the cable
run.
For your safety, DO NOT connect or disconnect any solar cables when there is current
running through them.
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CHARGE CONTROLLER & INVERTER WIRING
1Wire the positive(+) 6mm2cable from the charge controller to the C32 circuit breaker.
Wire the negative(-) 6mm2 cable from the charge controller to the C32 circuit breaker.
2

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4Wire the positive(+) 25mm2cable from the inverter to the C125 circuit breaker.
Indicator is green, showing the
circuit breakers are switched off
Ensure all circuit breakers are switched off before wiring (switch down, indicator showing
green.
3

Charge Controller & Inverter Wiring
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5
6
Wire the negative(-) 25mm2 cable from the inverter to the C125 circuit breaker.
Wire the positive(+) 16mm2 cable from the charge controller to the C63 circuit breaker.

Charge Controller & Inverter Wiring
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7Wire the negative(-) 16mm2 cable from the inverter to the C63 circuit breaker.

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BATTERY WIRING
1
30cm Battery
Link Cable
When wiring the blue cables, ensure that you fully attach
each cable at both ends before moving onto the next.
Wire the 25mm23m set of red and black cables to the inverter through the C125 circuit
breaker.
To minimise risk, we recommend only running one cable at a time and completely
terminating the connections before moving onto the next starting at the breaker.
When running the wires from the battery bank to the circuit breaker, be very
careful not to touch the positive to the negative. This will cause a short circuit,
which will result in a spark and possibly cause damage to the batteries or cables.
2
The battery bank is wired with four 12V batteries in series. This creates a 48V battery bank.
The large gauge cable is used to connect the batteries together in series.
Wire the four batteries together from negative to positive with the blue battery link cable.

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Wire the remaining set of red and black 16mm2cable to the charge controller through
the C63 circuit breaker.
3

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STARTUP PROCEDURE
66V
SELECT ENTER
PV
70v
66V
SELECT ENTER
PV 105V
66V
SELECT ENTER
PV
70V
1
2
Switch on the circuit breakers in the following order:
i) Battery to charge controller breaker C63.
ii) Battery to inverter C125.
iii) Panels to charge controller C32.
The green LED on the charge controller should be flashing, and the panel voltage should
be around 60V-80V in full sunlight. As this charge controller auto-detects voltage, it can
sometimes default to 12V on its first startup and give a battery over voltage warning.
To fix this, switch off all the circuit breakers in the reverse order of the previous step, and
switch them back on again in the correct order.