GRIDFREE Bach Hybrid Lithium Off Grid Cabin Kits Instruction Manual

: June 10, 2024
: GRIDFREE

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GRIDFREE Bach Hybrid Lithium Off Grid Cabin Kits Instruction Manual
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GRIDFREE Bach Hybrid Lithium Off Grid Cabin Kits Instruction Manual

WARNING – READ CAREFULLY

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.

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.

BACH HYBRID LITHIUM

Only some steps in this kit are 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. All steps after the section “Battery Wiring” are 240V AC and will require an electrician.

Installation of this kit legally requires an electrician.

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 info@gridfree.store.

We recommend reading these instructions in full prior to starting your install.

KIT CONTENTS

Kit Contents

Kit Contents Continued

REQUIRED TOOLS

Required Tools

SOLAR MOUNT OPTIONS

Solar Mount Options

WIRING OVERVIEW

Wiring Overview

SOLAR PANEL WIRING

Solar Panel Wiring Figure 1

1. Start 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.

Solar Panel Wiring Figure 2

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

Solar Panel Wiring Figure 3

3. Connect 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 Figure 4

4. Run the 6mm2 PV solar cables from the solar panels back to the C32 circuit breakers, and cuit it to length.

DO NOT connect the cable run to the solar panels as the cables will become live. Wait until all solar wiring is complete

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.

Solar Panel Wiring Figure 5

5. 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.

Solar Panel Wiring Figure 6

6. 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.

HYBRID INVERTER WIRING

Hybrid Inverter Wiring Figure 1

1. Run the excess 6mm2 positive(+) and negative(-) cables from the C32 circuit breaker to the hybrid inverter.

Hybrid Inverter Wiring Figure 2

2. Before proceeding to connect the hybrid inverter to the 200A MCCB circuit breaker, align the 35mm² x 1m cables between the components to ensure that the M6 ends (smaller holes) are inserted into the hyrbid inverter, and the M8 ends (larger holes) are inserted into the circuit breaker.

Hybrid Inverter Wiring Figure 3

3. Ensure all circuit breakers are switched off before wiring (switch down, indicator showing green.

Hybrid Inverter Wiring Figure 4

4. Wire the positive(+) 35mm² M6+M8 cable from the hybrid inverter to the 200A MCCB circuit breaker.

Hybrid Inverter Wiring Figure 5

5. Wire the negative(-) 35mm² M6+M8 cable from the hybrid inverter to the 200A MCCB circuit breaker.

BATTERY WIRING

Battery Wiring Figure 1

1. Follow the manual included by Growatt for stacking and mounting the batteries. Using the battery cables supplied in the battery cable set and in the individual battery boxes, connect the positive terminals as shown in the diagram above.

Battery Wiring Figure 2

2. Connect the power connections, following the instrctions detailed in the battery installation manual.

Battery Wiring Figure 3

3. Connect the CAN communication cables as described in the battery installation manual.

Battery Wiring Figure 4

4. Once you have wired the batteries into the inverter and charge controller, your completed wiring should look like the image above (excluding the panels). Double check everything is wired correctly and tightened before proceeding to prevent damage to your system.

Further steps will legally require an electrician.

Battery Wiring Figure 5

5. If using the utility / generator input, use components rated for 50A. If using components rated for less (e.g. a caravan plug), make sure to use an appropriately sized breaker.

Battery Wiring Figure 6

6. The output of the inverter is designed to wire into a distribution board.

STARTUP PROCEDURE

Startup Procedure

1. Power on all the lithium batteries by:

i) flicking the breaker switch at the back of the battery to “ON”
ii) pressing and holding the power button at the front until the green light turns on

Startup Procedure Figure 2

2. Switch on the circuit breakers in the following order:

i) Battery to hybrid inverter breaker 200A DC MCCB.
ii) Panels to C32 circuit breaker.

Startup Procedure Figure 3

3. The green LED on the PV Charge should be flashing, and the panel voltage should be around 60V-80V in full sunlight.

Startup Procedure Figure 4

4. Flick the switch located at the bottom of the hybrid inverter to “ON”, and refer to the hybrid inverter manual to ensure normal operation.

Startup Procedure Figure 5

i) Select the Lithium battery charging mode on the hybrid inverter.
ii) Press and hold “ENTER” for 3 seconds.
iii) Go to program 5 and set the battery type to “LI”.
iv) After pressing “ENTER”, it will automatically switch to Program 36.
v) Press “ENTER” again to enter Program 36.
vi) Set Program 36 to L51 and press “ESC”.

If there are any issues, please check all cables and connections. Then, double check Program 5 is LI and program 36 is L51.

TROUBLESHOOTING GUIDE

We’ve compiled this list of common problems our customers may encounter with their solar gear to help you solve any issues as fast as possible.

Please contact us if you don’t find the answers you need here or if your issue continues after implementing the given solutions.

1. My solar panels are not putting out as much power as normal

Once you’ve determined the drop in power is not due to weather changes, check your panels for any shade or shadows. Check both morning and afternoon in case the shadows are inconsistent. Ensure they’re adequately cleaned, as things such as thick dust or bird droppings can affect your output. Finally, double check all your connections are clean and secure.

If none of these issues are causing your power drop, you’ll need to send us clear pictures of your charge controller readings. We need to see the battery voltage, solar panel voltage, and solar panel amps. Please send readings from mid-day with peak sun and the end of the day or early morning.

2. My inverter keeps shutting off

Check your battery voltage, as inverters have an auto shut-off feature to protect them from damage when the voltage drops too low. The manual with your inverter will have this information and a troubleshooting guide.

4. My batteries aren’t charging

It’s likely your batteries have been drawn very low and cannot charge fully if you continue to draw power. Check all the wiring is secure and undamaged, then turn off the breaker between the batteries and the inverter, leaving the others on, and let the batteries charge back up to full.

If you don’t believe you have knowingly used enough power to drain the batteries, check all your appliances to see if something is using more power than it should.

5. My batteries drain very fast when the sun goes down

The controller may read 100% while charging at the higher voltage, but it will quickly drop lower when no charge is applied. This could be because the batteries charge at a higher voltage, so when the sun goes down, the battery voltage will stabilise at a lower level. It may also mean the batteries have been drained low, and they need to get more charge to be fully charged by the end of the day.

Try reducing your power usage for a few days to ensure the batteries are fully charged. You should also check that the solar panels have total sunlight exposure or whether an appliance has been left on. When customers notice less solar output, the most common cause is shading – as we transition between winter and summer, the sun’s path changes and can cast new shadows across the panels, which weren’t noticed when you first installed the system.

6. My inverter beeped, and an orange light was flashing

If you check quickly, you may hear your charge controller beep and see an orange light blinking.
This occurs when the battery voltage is too high, and the charge controller is charging the batteries completely.

This usually happens on a very sunny day or when using a high-draw appliance (e.g. toaster). When the high-draw apparatus stops, the solar works very quickly to top off the batteries and can peak the voltage briefly. As it’s a smart inverter, it works to protect itself and your batteries, so it can sometimes be a little bit on the overprotective side.

7. My inverter fan turns on all the time

You may notice the fan turning on even when you’re not using a high-load appliance. The inverter can sometimes be a little overprotective of itself, especially on warm days, and the fan will turn on when it doesn’t seem necessary. Make sure there is sufficient airflow around your inverter, and you should be fine.