ASHAPOWER NEON-30 12V Solar Mppt Charge Controller User Manual

ASHAPOWER NEON-30 12V Solar Mppt Charge Controller

SOLAR MPPT CHARGE CONTROLLER

ASHAPOWER® NEON-30Vers.6.6 Solar MPPT Charge Controllers are multi voltage range devices with unique features.The same device can be used for battery banks ranging from 1 Battery (12V) up to a battery bank of 4 batteries (48V) in series. The battery voltage
is selected by the device itself when we connect the battery bank across its terminal. The device gives a configurable charging current up to 30A.The Max PV panel
input open circuit voltage up to 140V makes it easier to group the panels conveniently. Also, sleek & stylish design of the product gives a better aesthetic view so that you can wall mount the product in a visible place inside your home or office.

SALIENT FEATURES

• Compatible for 12V/24V/36V/48V Battery Bank
• Auto-Detection and setting of Battery Bank.
• Multi stage Smart charging for prolonged battery life. (Bulk-absorption-float)
• Programmable Initial limited ampere charging facility Ultra-fast & efficient (98.9%) power point tracking.
• PV panel reverse polarity protection.
• Automatic disconnection of PV panels at night.
• Over voltage and overload protection from PV panels. Protection for battery against hardware failures.
• 10 menu custom function settings and inbuilt settings keys
• Grid power Control to the connected inverter

SPECIFICATIONS

• Max PV Array Open Circuit Voltage (Voc)
  • 12V/100V Voc
  • 24V/140V Voc
  • 36V/140V Voc
  • 48V/140V Voc
• Max PV Array in Watts Applicable
  • 12V/400Wp
  • 24V/800Wp
  • 36V/1200Wp
  • 48V/1600Wp
• Nominal Battery Voltage
  • 12V/24V/36V/48 V (Auto Setting)
• Maximum Charging Current
  • 30A
• Battery charging stages
  • Bulk, absorption, float
• Maximum Tracking Efficiency
  • 98.9%
• Standby Power Consumption
  • <1.5W
• Overload Protection
  • ✔
• Over Charge Protection
  • ✔
• Panel Reverse Polarity Protection
  • ✔
• Battery Reverse Polarity Protection
  • Optional
• Dimensions – L x W x H (mm)
  • 320x190x110.
• Net Weight (Kgs)/ Gross Weight (Kgs)
  • 3.4Kgs / 4.5Kgs
• Connector
  • Input / Output Terminal Block
• Display
  • 2 x 16 LCD Display

KNOW YOUR DEVICE

1 **LED INDICATORS**

2 **2×16 LCD
3 ****SETTINGS BUTTON [ENTER]
4 ****SETTINGS BUTTON [        ]
5 ****SETTINGS BUTTON [        ]
6 ****MPPT ON/OFF SWITCH
7 ****GRID BYPASS SWICH
8 ****TERMINAL COVER
9 SOLAR/GRID MONITOR PORT
10 I/O POWER TERMINALS**

INDICATOR

|

ON

|

OFF

|

BLINKING

---|---|---|---

BLUE

SOLAR / GRID POWER STATUS

|

LOAD IS ON SOLAR POWER

|

LOAD IS ON GRID POWER

|

BATTERY LOW WARNING TO DISCONNECT HEAVY LOADS

GREEN

SOLAR PRESENCE

|

PV PANEL VOLTAGE IS HIGHER THAN BATTERY BANK VOLTAGE / PV PANEL CONNECTION IS READY

|

PV PANEL VOLTAGE IS LOWER THAN BATTERY BANK VOLTAGE / PV PANEL CONNECTION NOT READY

|

–

RED

SOLAR CHARGING STATUS

|

SOLAR CHARGING CURRENT IS ABOVE 2AMPS

|

SOLAR CHARGING

CURRENT IS BELOW 2 AMPS.

CHARGING IS STILL GOING ON IN LOW AMPS

|

BULK CHARGING INDICATION

INSTALLATION & OPERATION

1. PV Panel Grouping: Group the PV panel array using standard Solar MC4 connectors and parallel connectors as to the recommended grouping example chart provided. Good quality weather proof solar DC cables must be used (4sq,6sq,10sq).
2. Battery Bank Setup linking cables tightly and check each battery separately for specific gravity and backup.The length of the connecting cable from than 1.5 meter. ( 16sq.mm/10 sq.mm)
3. MPPT Charge Controller Installation
4. Mount the MPPT charge controller vertically on the wall using the wall mount clamp provided.It is better to isolate MPPT from the wall, mounting it on a PVC board (kitchen cutting board) in order to avoid lightning hazards and earth leakage problems.
5. Never keep any object on the device blocking the cooling fan.
6. Avoid exposure to rain, direct sunlight or high temperature.
7. Switch off the device and remove the terminal cover
8. Connect the device to the battery bank using 16sq.mm/10 Sq.mm standard electrical cables up to the 1.5-meter length.
9. Connect the cables from PV panels to the solar power terminals of the device with the correct polarity. Reverse polarity will spoil the machine
10. Switch ON the Power switch of the device.(6) Three LED indicators and a cooling fan of the device start functioning for 5 seconds and goes off.
11. If more than one battery is used, connect the inter PPT to the battery must be less

Display s h ows the voltag e of the connected battery bank and applica ble range of PV Panel Open Circ uit Voltage (Voc) limit for the connected batt ery bank.Ensure the displayed ba ttery ban k voltage an d connected battery bank voltage is same when MPPT is powered ON. The Charger starts functioning when the PV Panel voltage detected is higher than the connec ted b attery bank voltage and green LED glows. If the PV pa nel voltage goes bel ow the batt ery bank volt age the green indicator goes off. When the device detects more than 2 Am p charging current to the battery, RED LED glows. If the current is less than 2Amp the RED LED goes off but charging continuous in low Am.p. When the battery voltage reaches 14.2V(Neargravity level – Configurable) the BLUE LED glows and the phase input to the inverter connected through the MPPT will be blocked. Now the load starts functioning on inverter(Solar). When the solar charging current stops, the current for the load will be taken from the battery bank and the battery voltage goes down. Once it reaches 11.5V(Configurable) charge controller shifts the load from inverter to grid power and the blue LED goes off. Blinking of the blue led indicates low battery volt and warns to disconnect heavy load.
Blinking of RED LED indicates Bulk charging mode.
When bulk charging completes blinking stops and MPPT enters float charging mode.

Automatic Grid power/ Solar Power Change Over using MPPT charge controller

(Converting a Home Inverter to a Smart Solar Inverter – Solar Management Unit – SMU )

If the Automatic Grid/Solar power Change Over is required , follow the instructions below: – Connect the Grid power phase wire (using 4sq.mm/6sq.mm) to the ‘Phase In’ part of the terminal on the device. Connect another wire from the ‘Phase Out’ part of the terminal to the input phase connector of the inverter. For automatic change over function(gridtosolar /solar to grid) keep the GRID BYPASS switch in ON position. When kept it in OFF position Inverter will always be on Gridpower. MPPT disconnects grid power to inverter when the battery terminal volt reaches 14.2V (Default) and reconnect grid power when terminal volt goes down to 11.5V (Default) (Never connect the neutral of the Grid power to any terminal of thecharger. Refer examples of Connection diagram provided).

Display Parameters

• E-Today :- Everyday total solar energy harvested in units. This value disappears overnight and added to units on the next day.
• Units :- Total solar energy harvested in units. This value reset when comes over 600 units or when battery power to MPPT is disconnected.

EXAMPLES FOR GROUPING OF PV PANELS

Follow These Examples to Achieve maximum MPPT performance

Battery Bank Volt

|

Max.PV Panel Voltage Range ( Voc )

|

Examples for Grouping PV Panels in Series

|

Max.PV Panels Applicable

in Watts

---|---|---|---

12V

|

30-100V

|

1) 21 Voc(100W panel) x 4 panel in series=84Voc=400W

2) 47 Voc(375W panel) x 1

|

400W

24V

|

50-140V

| 1) 47 Voc( 375W panel) x 2 panel in series= 94Voc=750W

2) 21 Voc(150W panel) x 5 panel in series=105Voc=750W

|

800W

36V

|

70- 140V

|

21 Voc(100W panel) x 6 panel in series=126Voc=600W x 2 strings in parallel=1200W

|

1200W

48V

|

100- 140V

|

36 Voc(260W panel) x 3 panel in series =108Voc=780W x 2 strings in parallel=1560W

|

1600W

Note: Solar panels should be grouped in such a way that the Open Circuit Voltage (Voc) of the panels connected in series should not exceed the Maximum panel voltage mentioned above for each battery bank!

CONNECTION DIAGRAM

400W/12V OFF GRID SOLAR POWER PLANT

800W/24V OFF GRID SOLAR POWER PLANT

1600W/48V OFF GRID SOLAR POWER PLANT

TROUBLESHOOTING

EV

| ****

PV PANEL VOLTAGE ERROR

| ****

PV PANEL VOLTAGE IS NOT IN THE SPECIFIED LIMIT. CHECK FOR PV PANEL GROUPING. REFER PV PANEL GROUPING MANUAL PROVIDED.

EB

| ****

BATTERY BANK VOLTAGE ERROR

| CONNECTED BATTERY BANK VOLTAGE IS NOT IN THE SPECIFIED LIMIT. CHECK FOR DEFECTIVE BATTERIES AND NUMBER OF BATTERIES.

ET

| ****

HIGH TEMPERATURE

| ****

CONNECTED PV PANEL CAPACITY (WATTS) IS NOT IN THE SPECIFIED LIMIT OR CHECK FOR THE FUNCTION OF THE COOLING FAN.

 |  | LIGHTNING MAY CAUSE
 |  | HARDWARE FAILURE. IF
 |  | CONTINUOUS BEEP SOUND
 |  | AND ERROR MESSAGE EM
 |  | IS SEEN,DISCONNECT THE
EM| HARDWARE

FAILURE

| PV PANELS BEFORE SWITCHING OFF THE
 |  | DEVICE.THEN SWITCH
 |  | OFF THEDEVICE.
 |  | CONTACT THE
 |  | INSTALLER FOR SERVICE
 |  | ASSISTANCE.
 | ****

HARDWARE ERROR

| ****

EARTH LEAKAGE FROM THE WALL MAY CAUSE HARDWARE ERROR MESSAGE .UN-MOUNTTHE DEVICE AND ISOLATE IT FROM THE WALL MOUNTING ON A PVC OR WOODEN BOARD

What is initial limited ampere charging in MPPT charge controller?

Maximum recommended charging current for a solar C10 inverter battery is up to 20% of the battery Ah. Batteries used in solar power system is
often discharged below 11.5V every day. So it is recommended to start initial charging with limited ampere instead of charging with maximum capacity of MPPT charge controller.
Eg : Recommended maximum charging current for a 12V,150Ah lead acid (C10) battery is 30 Amp. If such a battery is connected to MPPT delivering above30 amps current the excess ampere entering the battery can be controlled in the initial charging stage by activating initial limited ampere charging feature.MPPT delivers only 20% of the battery Ah initially. ie.30amps to the battery if the battery Ah limit is set to 150.(7th menu in function settings page 14)

1. Ampere Limiting based on load shifting voltage: (grid to solar shifting volt) In this mode battery charging ampere is limited in the initial stage .(if battery is 150Ah charging current will be limited to 30 amps.) When load is shifted to solar, entire ampere is shared between load and battery.
2. Ampere limiting based on Charging mode : In this mode also, battery charging ampere is limited in the initial stage and the limitation is stopped after the completion of bulk charging stage. (when float charging starts) ie.The entire charging current is never delivered to battery in float charging mode as the battery is already charged to float charging level.

MPPT charge controllers are sun light dependent devices and they can’t deliver high ampere in the morning. They start to charge the batteries in low ampere early in the morning. As the terminal volt of the battery increases, charge controller shifts the connected inverter load to solar power and the current is shared to load and battery charging.Hence the activation of limited ampere charging is not necessary in low ampere charge controllers connected with high Ah batteries. eg: If the charge controller delivers more than 30amp current in starting stage and the connected battery is below 150Ah it is recommended to activate limited ampere charging option.

Enabling limited ampere charging in MPPT charge controller.

Enter settings menu 10. AMP-LT (Read page 14 for MPPT function settings)

1. Select option “0” to disable limited ampere charging.

2. Select option “1” for limited ampere charging up to the set value of 4th menu.(4.GRD-SOL) ( Grid to Solar shifting volt 14.2V default) eg: When kept in this mode MPPT delivers only 30 amps of continuous charging current to the battery, if Ah of the battery is set to 150 and delivers maximum available ampere to load and for battery charging after shifting to solar power.

3. Select option “2” for limited ampere charging up to the set value of 2nd menu.(Bulk charging limit. 14.8V default)
   MPPT delivers only 30 amps of continuous charging current to the battery if the Ah is set to 150 and releases the ampere limit only after the completion of bulk charging (14.8V in default). In this mode, load is shifted to inverter only after starting float charging. (end of bulk charging)

4. Note: Before changing the default settings values of the device, ensure the maximum ampere and voltage ratings applicable for your battery type and brand (SMF, LEAD-ACID, GEL) This device is not suitable for direct charging of Lithium phosphate batery. Blind settings may cause severe damage to the batteries and charge controller. Default values given a re for C10 solar lead acid batteries. Refer user manual of connected battery for voltage and ampere settings.

CAUTION

• IT IS BETTER TO NOTE DOWN THE DEFAULT SETTINGS VALUES BEFORE MAKING CHANGES.
• NEVER TRY TO CHANGE THE DEFAULT SETTINGS OF THE DEVICE WITHOUT PROPER TECHNICAL ADVICE

ENTERING SETUP MODE :- Before entering setup read user manual carefully. Connect the charge controller to the desired battery bank. Switch off the device using MPPT ON/OFF switch (switch 6)
Press and hold ENTER button (3) on the front panel and switch on the device. Release when the display shows SETUP. Device enters to the setup menu 1. All LED indicators and fan starts to function. Press the ENTER button again to go to next menu. ( It is better to note down the default settings values before changing – (Refer Mppt Settings Page  Page 14) .Use the PLUS and MINUS buttons (button 4 and 5) to increase or decrease the default values. Device saves the changes when kept idle for 5 seconds or scroll through all menus.

MPPT FUNCTION SETTINGS **** NEON-30 Vers.6.6

MENU| TYPE| DESCRIPTION| RANGE
MIN| DEFAULT| MAX
1.FLOAT- V

Battery float charging limit ( If the Red LED indicator is steady,charger is in float charging mode )

| ****

SETTINGS

| Limit the float charging voltage recommended for the batteries

This value varies in different types of batteries. Default value given is forC10 grade solar lead acid batteries.For SMF and Gel batteries this value is between 13.0V to 13.8V.Refer battery user manual to change the value

| ****

13.0V

| ****

14.2V

| ****

15.5V

2.BULK- V

Battery bulk charging limit

( Blinking of Red LED indicates bulk charging mode )

| ****

SETTINGS

| Limit the maximum bulk charging voltage recommended for the batteries. This value varies in different types of batteries. Default value given is forC10 grade solar Lead acid batteries.For SMF and Gel batteries this value is between 13.5V to 14.5V (Refer battery user manual before changing )| ****

13.5V

| ****

14.8V

| ****

16.5V

3.MAX – AMP

Set the output ampere of MPPT

| ****

SETTINGS

| Limit the charging current to the battery if needed.(maximum charging current is recommended as 20% of the Ah of a single 12V,C10 solar lead acid battery.Eg: for a 150Ah battery, 30ampere is the maximum charging current recommended.Refer bat.user manual before changing the value.| ****

3A

| ****

30A

| ****

30A

4.GRD- SOL

Set grid power to solar power shifting voltage

| ****

SETTINGS

| If grid power is connected to inverter through MPPT to shift the load automatically from grid power to battery power(solar power) set the changeover battery voltage preferred.| ****

12.0V

| ****

14.2V

| ****

16.0V

5.SOL- GRID

Set solar power to grid power shifting voltage

| ****

SETTINGS

| Set the shifting (changeover) battery voltage preferred to change the load automatically from solar power (battery power) to grid power| ****

9.0V

| ****

11.5V

| ****

16.0V

6.BLK- LED

Battery low volt warning limit

| ****

SETTINGS

| Blinking of blue LED indicates low battery volt. Set this value above the vale given in the 5th menu .SOL-GRID changeover| low bat| 11.7V| 16.0V
7.BAT- AH

Set the Ah of the connected battery

| ****

SETTINGS

| Set the Ah of the connected battery bank to limit the bulk charging time Eg: if two 150Ah battery is connected in series set the value 150Ah and if connected in parallel set as 300Ah.| ****

10Ah

| ****

150Ah

| ****

600

Ah

8.CAL- AMP

Ampere calibration settings of MPPT

| ****

CALIBRATION

| ****

When MPPT charging is going on connect a true RMS DC clamp meter (Fluke brand is better ) over the positive battery wire and ensure the same reading is seen on the MPPT display.Calibrate and correct if there is difference.If the reading is less in clamp meter increase 2 or 3 points using UP button and save changes.If the reading is high in

the clamp meter decrease 2 or 3 points and save the changes.

Repeat the charging &setting process till both display shows same reading

| ****

110

| ****

130

| ****

160

9.CAL- VOLT

Volt calibration settings of MPPT

| ****

CALIBRATION

| ****

Note the battery volt reading on the MPPT display.Measure battery terminal volt using a true RMS DC volt meter.If there is difference in reading UP or DOWN the default value till both readings are equal.

| ****

–

| ****

–

| ****

–

10.AMP- LT

Settings for initial limited ampere charging.

Initial Charging ampere is limited to 20% of the Ah of the connected battery.

| ****

SETTINGS

| Activate this option when the charger is connected with low Ah batteries. eg: If the connected battery is below 150Ah and the charger delivers above 30amps continuous current .

A)  Select option “0” to stop all initial limited ampere battery charging

B)  Select option “1” to start initial limited ampere charging up to the set value of 4th menu.(Grid to solar shifting volt)

C) Select option “2” to start initial limited amp charging up to the set value of 2nd menu. (Bulk charging voltage)

Ampere limitation stops when float charging starts and only then load is

shifted to solar mode.

| ****

–

| ****

“0”

zero

| ****

–

MPPT FUNCTION SETTINGS

CONVERTING A NORMAL INVERTER TO A SMART SOLAR INVERTER
USING MPPT CHA RGE CONTROLLER
Before starting it is better to make a plan of your solar energy needs and ensure your existing inverter and batteries are suitable for solar application. When a battery is charged with a limited charging ampere (6AMP to 10 AMP) for long hours it delivers good energy backup. Solar charging and discharging is a daily process with high current from solar panels. We get only 4 to 5 hours of average sun light in a day and have to charge the batteries in this time. C10-grade solar batteries above 100Ah have the capacity to handle high-current charging and discharging. Usually, inverter batteries are either C20 grade or C10 grade normal batteries. An inverter battery is always connected to grid power and continuously charges the batteries in a limited ampere for long hours (6 AMP to 10 AMP) and gives good backup. That is why we don’t get enough backup from normal batteries when charged from solar power with a high current. If we use normal batteries for solar charging with the limited charging current they can’t be got fully charged before evening. So always insist on C10-grade solar batteries for solar applications.
Now check your home inverter is provided with a grid charging ON/OFF switch.
Most of the branded normal-type inverters are not provided with a grid charging ON/OFF switch on them. When we use this type of normal inverter in solar off-grid syste m it will charge batteries from grid power and we do not get the actual solar benefit.

HOW THE CHARGE CONTROLLER DRIVES THE CONNECTED INVERTER

Most of the solar M PPT charge controllers are provided with an in built relay to control grid power to inverter. Remove grid power phase wire from your inverter and connect to PHASE IN terminal of MPPT. Connect a wire from PHASE OUT terminal of MPPT to the phase in terminal of inverter. (Never connect neutral wire of grid power to any connectors of MPPT). When charging starts terminal volt of the battery rises to the preset voltage 14.2V (this value is adjustable) MPPT disconnects the AC mains to inverter and the connected load on inverter works on battery power (solar power). when the battery terminal volt goes down (in the evening or cloudy sky) and reaches 11.5V (this value is adjustable) MPPT reconnects grid power to inverter. If your inverter is a normal type without a grid charging disabling switch it will charge the batteries and we don’t get solar benefit. To overcome this it is better to limit the load on inverter and keep the battery terminal volt always high. Some customers use the solar power only at day time and shift the load to AC mains by keeping the shifting to AC mains voltage 12.0V or more. Fitting an external grid changeover relay system for bypassing grid power directly to load is also applicable. If we use an inverter with grid charging ON/OFF switch we can keep the switch in off position to avoid charging from grid. Only on cloudy days we can keep the switch in on position and charge the batteries from grid power.

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 th at does not comply with the instructions, a faulty operation or inadequate maintenance.
11. The use of the charger 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

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