ASHAPOWER ROVER-5000LV-48V User manual

1
MODEL: ROVER-5000LV-48V
I N N OV AT I NG TOMORROW
SOLAR MPPT PCU
USER MANUAL
ISO
CERT IFIED
900 1: 201 5
HS
COMPLIANT
Vers.5.1
HIGH PERFORMANCE WITH LOW ENERGY CONSUMPTION
48V -5KVA
3.5KW PV PANEL
60AMP/185Voc
MPPT SCC
INVERTER
GRID CHARGER
20AMP
No load DC current 0.7A 0.3A
High grade
CRNO laminated
Pure Copper transformer
70 Micron High grade PCB
0.8 Constant output power factor
(
5 000VA = 2400W max. O/P load)
Pick & Place type circuit
Design for quick service
Maximum MPPT tracking
Efficiency up to 98.9%
Constant output Voltage
(222V) even on heavy loads
User configurable
Function settings
PV Panel Voc upto
185 Volt
-
+
Charging Priority control facility
Grid charging ON-OFF control
Grid priority,Solar priority

stylish design : Makes you proud to place the device in a visible place at your
home/office
*Unique ZMPT based isolated grid sensing : Reduces chances of MOSFET
failure on lightning & external surges.
*Forced grid to solar shifting facility: Helps customer to use maximum solar
power *Sleek and stylish design : Makes you proud to place the device in a
visible place at your home/office
power *Sleek and stylish design : Makes you proud to place the device in a
visible place at your home/office
2
ASHAPOWER
SOLAR MPPT PCU
MODEL: ROVER 5000LV-48V
UNIQUE FEATURES
185Voc-60Amp-3.5kw PV load and 4Kw Inverter combination assure continuous
day time heavy load operation without disturbance to batteries
High power inverter and MPPT integration
Standby zero grid power consumption
Once the battery is fully charged frequent relay controlled isolation of grid power
from charging transformer ensures standby zero grid power consumption saving electricity
Constant noise free DSP pure sine wave output
Ensures best life and flicker free working of digital equipments
Large 4Line multifunctional LCD front panel display
Gives detailed and clear system information at a look
Soft front panel all function control switches
Helps easy finger tip system control and function settings
Pure Copper Transformer with high grade Lamination
Ensure minimum no load DC current (0.8 PF) and saves generated solar power
Intelligent true multi stage smart solar and grid charging
Ensures prolonged battery backup and life
Battery grid charging even at low grid voltage
Suitable for places with low grid voltage areas
High over load and surge load handling capacity
Trouble free running of loads with initial heavy input surge
MCB short circuit protection for grid power
Ensures system safety and avoids frequent fuse changing
Over load,surge and short circuit protection
Protection for internal component failure
All type battery compatibility
Supports tubular lead acid, flat,SMF,Gel,batteries. Branded LiFeO4
batteries with BMS can be connected with the support of the battery supplier
Unique ZMPT based isolated grid sensing
Reduces chances of MOSFET failure on lightning and external surges
Forced grid to solar mode shifting facility
Helps customer to use maximum harvested solar energy
Bulk,Absorption,Float (User configurable battery charging voltage)
Customer control over grid charging ON/OFF option.
Blocks battery charging from grid power saving electricity
User selectable solar priority and grid priority charging modes
Helps customer to select charging mode as per the power conditions of the site
ASHAPOWER SOLAR MPPT PCU ROVER-LV-5000- 48V is a Premium quality
high power Solar energy extractor for your Home/Office having a connected
load of 4000Watts. It can be loaded with Air conditioner, Induction cooker, Fans,
LED lights, Computer, LED TV, Washing machine, Laser printer, Refrigerator,
Iron box, and an Induction motor pump when used with 4500 watts Solar PV
panels and 48V / 200Ah batteries. The integration of an efficient MPPT SCC
(185Voc/60AMP/3.5kwp), 48V/4000W pure sine wave inverter, powerful grid
charger and high performance with low energy consumption makes it unique in
its class.

Nominal Battery Voltage
Maximum solar Charging Current
No load battery Power Consumption
Overload Protection From PV Panel
Over Charge Protection from grid and solar
Panel Reverse Polarity Protection
Battery Reverse Polarity Protection
Dimensions – L x W x H (cm) 47.7cmx25.3cmx39.2cm
Connectors
Display
48V DC
98.9%
Humidity 0 to 90% RH (No dew)
Operating temperature -20 degree to 65 degree C
-30 degree to 80 degree C
Storage temperature
Optional
YES
YES
YES
4line LC Display
Net Weight (Kgs) / Gross Weight (Kgs) 36.9kg/39.7kg
Solar MPPT battery charging stages Bulk-Absorption-Float
6Way Input/Output Terminal block
Max. Applicable PV Panel Load on MPPT
Maximum MPPT tracking efficiency
3000wp/185Voc - 3500wp if Voc <140V
Max. Applicable PV Panel Voc
Maximum grid battery charging current
4 AMP TO 15AMP
(selectable)
Standby grid Power Consumption Zero at idle stage
GRID POWER ON BATTERY LOW OVER LOAD
FORCED
SHIFTING
DSP SINE WAVE
SOLAR MPPT PCU
LOAD ON SOLAR GRID CHARGING SOLAR CHARGING
4x16 LCD DISPLAY
LED INDICATORS
FUNCTION KEYS
COOLING FAN
AC MAINS MCB
BATTERY DC INPUT
CONNECTION TERMINAL BLOCK
7
6
5
4
3
2
1
2
1
35
7
6
PHASEONLY
SOLARPANEL
EARTH
+_
+_
GRID
PHASE
IN
GRID
NEUTRAL
IN
GRIDPOWERON BATTERYLOW OVERLOAD
FORCED
SHIFTING
DSPSINE WAVE
SOLARMPPT PCU
LOADONSOLAR GRID CHAR GING SOLARCHARGING
4
INVERTER
OUTPUT
TO LOAD
0.7AMP +.3
-
Grid power battery charging stages Bulk-Float
GRID INPUT
3
60Amps (configurable)
BATTERY INPUT
48V/3200W INVERTER + 60AMP/185Voc/3kwp - MPPT SCC
KNOW YOUR DEVICE
ASHAPOWER SOLAR MPPT - PCU ROVER-5000-48V
185V
48V

GRID POWER ON BATTERY LOW OVER LOAD
FORCED
SHIFTING
LOAD ON SOLAR
GRID CHARGING ON SOLAR CHARGING ON
2
1
3
4x16 LCD DISPLAY
LED INDICATORS
FUNCTION KEYS
3
2
1
FRONT PANEL INDICATIONS
INNOVATING TOMORROW
SOLAR MPPT PCU
4

5
7
6
PHASE ONLY
SOLAR PANEL
EARTH
+
_
+_
GRID
PHASE
IN
GRID
NEUTRAL
IN
4
INVERTER
OUTPUT
TO LOAD
COOLING FAN
GRID POWERMCB
BATTERY DC INPUT
CONNECTION TERMINAL BLOCK
7
6
5
4
BACK PANEL CONNECTORS
GRID IN MCB
5
BATTERY INPUT
SOLAR INPUT
GRID & SOLAR CONNECTION TERMINAL BLOCK
(48V)

EXAMPLE FOR PV PANEL GROUPING
ASHAPOWER SOLAR PCU
48V/3200W/ 60AMP/185Voc
50 Voc,500W PV PANELS x 6
( 4 X 12V BATTERY / 200 AH)
+_
48 V B
ATTERY BANK
Total PV Panel Voc
150V
3000 W
Total PV Panel Load
Max PV.Panel Applicable in Watts : 3000w
Max PV.Panel Voc : 185V
SOLAR PANEL
EARTH
INVERTER
OUTPUT
TO LOAD
+_
+_
GRID
PHASE
IN
GRID
NEUTRAL
IN
PNP N
NP P
LOAD
GRID
POWER
6
GRID IN MCB
If Voc is below 140V 3500W panel can be connected
ASHAPOWER SOLAR-MPPT-PCU-ROVER-5000LV -48V CONNECTIONS

stylish design : Makes you proud to place the device in a visible place at your
home/office
*Unique ZMPT based isolated grid sensing : Reduces chances of MOSFET
failure on lightning & external surges.
*Forced grid to solar shifting facility: Helps customer to use maximum solar
power *Sleek and stylish design : Makes you proud to place the device in a
visible place at your home/office
power *Sleek and stylish design : Makes you proud to place the device in a
visible place at your home/office
GRID (AC MAINS) MODE PARAMETERS
GRID (AC MAINS) MODE BATTERY CHARGING PARAMETERS
Battery Charging Algorithm Bulk,Absorption,Float
Constant Charging Current 8 AMP (Selectable)
Default charging Priority Solar priority
Float Charging Voltage 13.8VX4 =(55.2V) Volt (user selectable)
Battery Bulk charging voltage 14.4VX4=57.6V) (user selectable)
Inverter Output Volage 222 Volt
Inv Output Frequency 50 Hz
Inverter Surge Rating for 2 Second 250 %
Battery high voltage trip 66 Volt
Battery Low Warning Level 44 Volt
Battery Low Trip Level 43.2Volt
Overload Warning Level 95 %
Overload Trip Level 100 %
Inverter mode audio alarm Buzzer beep
INVERTER (BATTERY) MODE PARAMETERS
Inverter Power factor 0.8
Inverter Output Wave form DSP pure sine wave
Typical transfer time ≤20 m second
Mains detection delay 10 Seconds
Input mains high cut voltage (Wide input) 280V (Selectable)
Input mains low cut voltage (Wide input) 100V (Selectable)
Input mains high restore voltage (Narrow input) 260V
Input mains low restore voltage (Narrow input) 180V
Grid input voltage range 100V-300V Volt
Grid input requency 50 Hz
MPPT Max Voc 185 Volt
MPPT Max Output Current 60 AMP
Solar battery Charging Algorithm Bulk,Absorption,Float
Default solar float charging voltage 13.8VX4 =55.2V) (selectable)
Default solar Absorption charging voltage 14.1VX4 =(56.4V (selectable)
Default solar Bulk charging voltage 14.8VX 4=59.2V (selectable)
MPPT SCC PARAMETERS
MPPT Max PV Panel load 3000wp/185Voc, 3500wp if Voc below 140V
7

Battery bank Voltage
Mains input Voltage
Inverter output frequency
Inverter Output Load %
Battery charging current from grid
Grid bypass status
Inverter ON/OFF Status
Warning Messages Bat low/Overload
Trip Messages
LCD DISPLAY INDICATIONS
Grid charging ON/OFF status
LED INDICATIONS
Grid power presence Red Grid power LED ON
Battery grid charging Yellow Grid Charger LED ON
INV Std by on Mains Green Inverter ON LED Blink
INV load on Battery Green Inverter ON LED steady
Over load Warning Red Overload LED ON
Overload Trip Red Battery low LED ON
Battery Low Warning Red Battery low LED ON
Inverter output Voltage
Solar charging Amp
Solar PV Panel watts
Solar PV Panel voltage
IMPORTANT GENERAL ELECTRICAL SAFETY PRECAUTIONS
Lead Acid Batteries Produce Hydrogen Gas Which is Highly Flammable
1) Never use a flame or any kind of spark producing device near fully charged batteries as it may cause
an explosion of the batteries and fire hazard (eg: Checking battery water level under a candle flame,
spark from metal cutter or spark from loose contact of battery connecting wires).
2) Maintenance of the batteries and pv panel array at regular intervals make the solar power system
trouble free and fresh.
3) Solar panels should be grouped in such a way that the maximum Open Circuit Voltage (Voc) of the
panels connected in series should not exceed the Maximum PV panel voltage recommended for each
Battery Banks.
4) Safety precautions must be taken while grouping and connecting PV panels to the charge controller
with high Voc input. (500 Volt DC current from the PV panel is highly dangerous. Never touch the
terminals without safety glows).
5) Extreme care should be taken while connecting High voltage solar power systems.
6) Earthing and wiring of high power solar system must be done under the supervision of a qualified
electrical engineer.
7) Never connect the PV panel connection to the battery input or the connection of the batteries to the
PV input.
8) Never connect any of the grid line to any of the DC (PV or Battery) connection terminals.
9) The installation and use must comply with the local safety instructions and standards in force.
10) We disclaim all responsibility and liability for damage, costs or losses resulting from an installation
that does not comply with the instructions, a faulty operation or inadequate maintenance.
11) The use of the
Home UPS
is in any case under the responsibility of the customer.
12) This equipment is neither designed nor guaranteed to installations used for vital medical care nor any
other critical installation entailing potential risks of damage to people or to the environment.
8
Solar charging Blue LED ON and steady
Solar ready (load on solar) Green load on solar LED ON and steady
( Red grid power ON LED blinking)

9
ASHAPOWER SOLAR-PCU INSTALLATION & OPERATION GUIDE LINES
1) Battery bank setup :
25 sqmm/16sq
i
nter
li
nking
cables to join the batteries
and tight them well.
Check each battery separately for specific gravity, same terminal volt
and good backup
Do
not use old
and new batteries together, either in parallel or in series.
distance from the wall.
in the circuit of o grid power plant, under the guidance of a qualified electrical engineer/electrician for safety
3)
Place of Installation
:
4) DCDB / ACDB & Surge protectos :
Place the solar PCU on a fixed stand in a well ventilated area keeping a 6 inch
It is recommended to connect DCDB / ACDB & lightning surge protectors
Avoid exposure to rain, dusty area, direct sunlight or in area having high temperature.
Now Connect the battery
wires with correct polarity to the connection
terminal blockof the device
(Reverse polarity will spoil the device)
and long life of the power plant. Never use substandard electrical materials for wiring.
2)
PV panel grouping: Group the
PV panel array using standard
s
olar MC4 connectors and parallel
connectors as to the recommended grouping example chart provided. Good quality weather proof solar
DC cables must
be used (6sqmm,10sqmm)
Use
LCD display shows battery voltage and default function parameters.
PV panel voltage and polarity is correct solar charging starts indicating SOLAR CHARGING LED glowing ON.
Connect the cables from PV panels to the solar positive and negative terminals of
the solar PCU.
If
the
When the connected battery vo
l
tage reaches GRID to SOLAR preset vo
l
tage (default 14.2V)
LOAD ON SOLAR
glows ON indicating the battery is nearly full charge and ready to use the connected
indicator LED
When phase and neutral of grid power is connected to the concerned grid terminals
,GRID POWER ON
indicator
glows ON.
inverter load.
Quick customer settings menu is provided with 6 options
1) UPS / INVERTER mode ON/OFF selection
2) Grid Charging ON/OFF selection and Grid and solar charging priority selection.
GUIDE LINES FOR QUICK CUSTOMER SETTINGS AND MAIN TECHNICAL SETTINGS
Two priority charging options are given.
Solar charging priority and grid charging priority
If Solar priorityis selected, battery charging will be from solar power.If the battery terminal volt is below
the inverter low warning level (10.7default for 1 battery) grid power is also used for boosting the batteries.
When solar power is not available battery charging will be fully from grid power in 8 amps (default)
If Grid priorityis selected device charges the battery both from grid and solar power simultaneously
3) Grid bypass ON/OFF Selection and Automatic grid to solar shifting selection
Three options are givn. If BV+PV+GRID option is selected system shifts to solar mode only if there is the
presence of grid supply,high battery terminal volt and solar PV presence.
If BV+PV option is selected system shifts to solar mode only if there is the presence of solar PV and
high battery terminal volt. If BV option is selected system shifts to solar mode whenever the battery
terminal volt becomes high from any charging source.
giving priority to grid.eg.If the grid charger is preset to10 amps and solar charging current is available
above this value system charges battery drawing10 amps fully from grid power and available current
from solar.
4) Gri - solar-V (grid to solar shifting volt selection)
5) Sol - grid-V (solar to grid shifting volt selection)
Customer can select grid charging OFF option to avoid all kinds of grid power charging.
MODEL : ROVER-5000 LV-48V
6) Sol - grid-Kwh (solar to grid shifting based on Kwh) (for Lithium batteries)

10
What is INVERTER mode
In this mode device shifts the load to inverter when the mains voltage drops below 100V
If UPS mode is activated in low grid power voltage areas (below 190V) load will be working
on battery backup , resulting more grid energy consumption for charging.So it is better
to activate INVERTER mode for normal house hold equipments as fans LED lights,mixer grinder
washing machines etc.
Which mode is better for house hold equipments
What is CHARGER ON/OFF in quick settings menu
This option helps the customer to control charging of batteries (ON/OFF) from grid power saving
electricity.
MAIN TECHNICAL SETTINGS GUIDE LINES
How to enter main customer settings menu
Before entering settings menu ensure to OFF the device by pressing OFF button
Press OFF button again and press ENTER button also without releasing OFF button
for 3 seconds.With a beep sound device enters main settings mode.Cooling fan starts
functioning
Consecutive pressing of the ENTER button helps to go to next menu.If kept for
5 seconds system saves the changes and exits from settings menu.
Follow the settings table given below.Refer battery user guide lines also
before changing the settings.Remember blind settings will spoil
the device and batteries.
What is UPS mode in Quick settings menu.
UPS mode is to shift the connected load on inverter from grid power to battery
power when grid power drops below 190V.
Fluctuations on grid power badly affect digital equipments as computers.
When the device is used for digital equipments as computers select UPS mode
in ON position. In this mode device automatically shifts from grid mode to
inverter mode when AC mains voltage drops below 190V preventing frequent
computer system restarting.
When solar power availability is weak grid charging option must be kept in ON
Press OFF button on the front panel
Press and hold ENTER button for 3 seconds.Device enters Quick settings mode
Press ENTER button again to go to next menu
How to enter Quick customer settings menu
To exit Quick settings menu go through all menu or keep the device idle for 8 seconds
Select the required option by pressing ON/OFF button
displaying UPS mode ON/OFF selection option.Cooling fan starts functioning.
mode to avoid battery deep discharging.
What is SOL-GRD-Kwh in quick settings menu
20 MENU CUSTOMER RELATED SETTINGS ARE PROVIDED.
OTHER ADVANCED SYSTEM SETTINGS ARE PASSWORD PROTECTED.
When Lithium batteries are connected, solar to grid mode
shifting is better to control on the basis of average harvestable
units per day instead of battery terminal volt based shifting.
(The default value10KWH is an average of 3.5 units from 1KW
solar panels to 12V/200Ah battery)