Renogy STARTER300D-W30 User manual

Renogy STARTER300D-W30 User manual
The Traveler Series TM : Wanderer
30A PWM
Solar Charge Controller
Version 1.0
Important Safety Instructions
Please save these instructions.
This manual contains important safety, installation, and operating instructions for the
charge controller. The following symbols are used throughout the manual:
WARNING
Indicates a potentially dangerous condition. Use extreme caution
when performing this task
CAUTION
Indicates a critical procedure for safe and proper operation of the
controller
NOTE
Indicates a procedure or function that is important to the safe and
proper operation of the controller
General Safety Information
Read all of the instructions and cautions in the manual before beginning the installation.
There are no serviceable parts for this controller. Do NOT disassemble or attempt to
repair the controller.
Make sure all connections going into and from the controller are tight. There may be
sparks when making connections, therefore, make sure there are not flammable
materials or gases near installation.
Charge Controller Safety
NEVER connect the solar panel array to the controller without a battery. Battery
must be connected first. This may cause a dangerous occurrence where the
controller would experience a high open circuit voltage at the terminals.
Ensure input voltage does not exceed 50 VDC to prevent permanent damage. Use
the Open Circuit (Voc) to make sure the voltage does not exceed this value when
connecting panels together in series.
The charge controller should be installed indoors in a well-ventilated, cool, and dry
environment.
Do NOT allow water to enter the controller.
01
Battery Safety
Do NOT let the positive (+) and negative (-) terminals of the battery touch each other.
Use only sealed lead-acid, flooded, gel or lithium batteries which must be deep cycle.
Explosive battery gases may be present while charging. Be certain there is
enough ventilation to release the gases.
Be careful when working with large lead acid batteries. Wear eye protection and
have fresh water available in case there is contact with the battery acid.
Over-charging and excessive gas precipitation may damage the battery plates
and activate material shedding on them. Too high of an equalizing charge or too
long of one may cause damage. Please carefully review the specific
requirements of the battery used in the system.
Equalization is carried out only for non-sealed / vented / flooded / wet cell lead acid
batteries.
Do NOT equalize VRLA type AGM / GEL / LITHIUM batteries UNLESS permitted
by battery manufacturer.
Default charging parameters in Li mode are programmed for 12.8V Lithium Iron
Phosphate (LFP) Battery only. Before using Wanderer to charge other types of
lithium battery, set the parameters according to the suggestions from battery
manufacturer.
WARNING
Connect battery terminals to the charge controller BEFORE connecting
the solar panel(s) to the charge controller. NEVER connect solar panels
to charge controller until the battery is connected.
02
Table of Contents
General Information
04
Optional Components
06
Identification of Parts
07
Installation
07
Mounting Recommendations
Operation
10
LED Indicators
10
System Status Troubleshooting
11
Maintenance
12
Fusing
12
Technical Specifications
13
Electrical Specifications
13
Battery Charging Parameters
13
Dimensions
03
07
14
General Information
The Wanderer is an advanced charge controller for off-grid solar applications and can be
used with a 12V battery or battery bank. Integrating highly efficient PWM charging, the
Wanderer increases battery life and improves system performance. The controller comes
equipped with fully comprehensive self-diagnostics and electronic protection functions to
prevent damage from installation mistakes or system faults.
Key Features
Optimized for 12 VDC system voltage
30A charging capacity.
Deep Cycle Sealed, Gel, Flooded and Lithium battery options.
4 Stage PWM charging: Bulk, Boost. Float, and Equalization
Temperature compensation and correcting the charging and discharging parameters
automatically, improving battery lifetime.
Protection against: reverse current, overcharging, short-circuit and reverse polarity.
Negative ground controller
Multiple LED indicators for easy to read charge status and battery information.
Remote temperature compensation compatible (accessory sold separately)
Integrated communication port for remote monitoring.
Charges over-discharged lithium batteries.
PWM Technology
The Wanderer utilizes Pulse Width Modulation (PWM) technology for battery charging.
Battery charging is a current based process so controlling the current will control the
battery voltage. For the most accurate return of capacity, and for the prevention of
excessive gassing pressure, the battery is required to be controlled by specified
voltage regulation set points for Absorption, Float, and Equalization charging stages.
The charge controller uses automatic duty cycle conversion, creating pulses of current
to charge the battery. The duty cycle is proportional to the difference between the
sensed battery voltage and the specified voltage regulation set point. Once the battery
reached the specified voltage range, pulse current charging mode allows the battery to
react and allows for an acceptable rate of charge for the battery level. The Wanderer
has a 4-stage battery charging algorithm for a rapid, efficient, and safe battery
charging. They include: Bulk Charge, Boost Charge, Float Charge, and Equalization.
04
Bulk Charge: This algorithm is used for day to day charging. It uses 100% of available
solar power to recharge the battery and is equivalent to constant current.
Boost Charge: When the battery has charged to the Boost voltage set-point, it
undergoes an absorption stage which is equivalent to constant voltage
regulation to prevent heating and excessive gassing in the battery. The Boost
time is 120 minutes.
Float Charge: After Boost Charge, the controller will reduce the battery voltage to a
float voltage set point. Once the battery is fully charged, there will be no more chemical
reactions and all the charge current would turn into heat or gas. Because of this, the
charge controller will reduce the voltage charge to smaller quantity, while lightly charging
the battery. The purpose for this is to offset the power consumption while maintaining a
full battery storage capacity. In the event that a load drawn from the battery exceeds the
charge current, the controller will no longer be able to maintain the battery to a Float set
point and the controller will end the float charge stage and refer back to bulk charging.
Equalization: Is carried out every 28 days of the month. It is intentional overcharging of
the battery for a controlled period of time. Certain types of batteries benefit from periodic
equalizing charge, which can stir the electrolyte, balance battery voltage and complete
chemical reaction. Equalizing charge increases the battery voltage, higher than the
standard complement voltage, which gasifies the battery electrolyte.
WARNING
WARNING
05
Once equalization is active in the battery charging, it will not exit this
stage unless there is adequate charging current from the solar panel.
There should be NO load on the batteries when in equalization
charging stage.
Over-charging and excessive gas precipitation may damage the
battery plates and activate material shedding on them. Too high of
equalizing charge or for too long may cause damage. Please carefully
review the specific requirements of the battery used in the system.
Lithium Battery Activation
The Wanderer PWM charge controller has a reactivation feature to awaken a sleeping
lithium battery. The protection circuit of lithium battery will typically turn the battery off and
make it unusable if over-discharged. This can happen when storing a lithium battery pack in
a discharged state for any length of time as self-discharge would gradually deplete the
remaining charge. Without the wake-up feature to reactivate and recharge batteries, these
batteries would become unserviceable and the packs would be discarded. The Wanderer
will apply a small charge current to activate the protection circuit and if a correct cell voltage
can be reached, it starts a normal charge.
Optional Components
The Wanderer is shipped with by itself with no additional components. Optional components
that require a separate purchase:
Remote Temperature Sensor (TS-R):
Measures the temperature at the battery and uses this data for very
accurate temperature compensation. The sensor is supplied with a 6.6ft
cable length that connects to the charge controller.
BT-1 Bluetooth Module:
The BT-1 Bluetooth module is a great addition to any Renogy
charge controllers with a RS232 port and is used to pair charge
controllers with the Renogy BT App. After pairing is done you can
monitor your system and change parameters directly from you cell
phone or tablet. No more wondering how your system is
performing, now you can see performance in real time without the
need of checking on the controller’s LCD.
06
Identification of Parts
4
Key Parts
3
1. Battery Select Button
2. Battery Type Indicator
3. Battery Indicator
4. PV Indicator
5. Remote Temperature Sensor Port (optional accessory)
6. PV Terminals
7. Battery Terminals
8. RS-232 Port (optional accessory)
5
6
7
2
1
8
Installation
WARNING
Connect battery terminal wires to the charge controller FIRST then connect the solar panel(s) to
the charge controller. NEVER connect solar panel to charge controller before the battery.
CAUTION
Do not over-torque or over tighten the screw terminals. This could potentially break the piece
that holds the wire to the charge controller.
Refer to the technical specifications for max wire sizes on the controller and for the maximum
amperage going through wires.
Mounting Recommendations:
WARNING
Never install the controller in a sealed enclosure with flooded batteries. Gas can
accumulate and there is a risk of explosion.
1. Choose Mounting Location—place the controller on a vertical surface protected
from direct sunlight, high temperatures, and water. Make sure there is good ventilation.
2. Check for Clearance—verify that there is sufficient room to run wires, as well as clearance
above and below the controller for ventilation. The clearance should be at least 6 inches (150mm).
3. Mark Holes
4. Drill Holes
NOTE
The Wanderer is not equipped with screws for wall mounting.
5. Secure the charge controller.
07
Battery
Solar Panel
08
Bluetooth Module Communication (optional)
Temperature Sensor (optional, not polarity sensitive)
Place the sensor close to the battery
09
Operation
After connecting the battery to the charge controller, the controller will turn on
automatically. Operation of this controller is very simply. Users set the battery type,
and leave the rest of the work to the charge controller.
Setting Battery Type
Simply hold the gray button for approximately 7 seconds until the LED flashes. Once
flashing, then press the gray button again to the desired battery type (they are color
coded) and simply leave the controller alone until the flashing stops (this should take
approximately 10 seconds). This indicates the parameter has been set.
NOTE
If the LED lights do not flash, hold the gray button for 7 seconds again,
release, and immediately press the gray button again to enable the flashing.
Set Battery Type
Sealed
Gel
Flooded
Li
LED Indicators
The Wanderer is a simple to use controller requiring little to no maintenance. Users can
be informed about the charge controller’s status based on the LED indicators at the PV
and Battery levels. The following chart goes into further detail regarding the Wanderer’s indicators.
PV Indicator
Fast
Flashing
Solid
BATT Indicator
Controller Status
n/a
PV terminal is over-voltage
n/a
PV terminal low output
Slow
Flashing
Solid
Slow
Flashing
Slow
Flashing
The battery is in float charge
n/a
Fast
Flashing
The battery is over-voltage
n/a
Solid
The battery is under-voltage
n/a
Solid
The battery is over-discharged
n/a
Slow
Flashing
Battery is charging normally
The battery is over-heating
10
System Status Troubleshooting
Description
Battery is low-voltage
Troubleshoot
Use a multi-meter to verify the rated battery voltage.
Disconnect any loads connected to the battery to allow it to
charge.
Battery is over-voltage
Use a multi-meter to check the voltage of the battery. Make
sure the battery voltage is not exceeding the rated
specification of the charge controller. Disconnect battery.
PV is over-voltage
Use a multi-meter to check the voltage of the panels.
Ensure that they meet the specification of the controller
to not exceed 25 VDC.
PV terminal low output
The PV output is typically lower in the early mornings
and in the late afternoons. This should not require
troubleshooting unless a solar panel is defective.
Battery is over-heating
When heat is exceeding the specification of the controller,
it will automatically shut down. The controller will resume to
operate once it interprets a change in temperature.
Other Considerations
11
Charge controller does
not charge during daytime
when the sun is shining on
the solar panels.
Confirm that there is a tight and correct connection from
the battery bank to the charge controller and the solar
panels to the charge controller. Use a multi-meter to
check if the polarity of the solar modules have been
reversed on the charge controller’s solar terminals.
No LED indicator when
battery is connected to
the charge controller
The battery voltage may be less than 9V. A minimum of
9V is required to power on the controller.
Battery LED light does
not flash when holding
for 7 seconds.
The battery selection LED must be enabled. Disconnect
the battery from the controller, then connect the battery to
the controller to reset it. Then hold the gray button for 7
seconds, release the button, and then immediately press
the gray button one more time to select a battery type.
Maintenance
For best controller performance, it is recommended that these tasks be performed from time to time.
1. Check that controller is mounted in a clean, dry, and ventilated area.
2. Check wiring going into the charge controller and make sure there is no wire damage or wear.
3. Tighten all terminals and inspect any loose, broken, or burnt up connections.
Fusing
NEC Maximum Current for different Copper Wire Sizes
AWG
Max.
Current
16
14
12
10
8
6
4
2
0
10A
15A
20A
30A
55A
75A
95A
130A
170A
Fuse from Controller to Battery
Controller to Battery Fuse = Current Rating of Charge Controller
Ex. 30A Wanderer = 30A fuse from Controller to Battery
Fuse from Solar Panel(s) to Controller
Ex. 200W; 2 X 100 W panels
Parallel
Total Amperage = Isc1 + Isc2 = (5.75A + 5.75A) * 1.56
Fuse = minimum of 11.5 * 1.56 = 17.94= 18A fuse
12
Technical Specifications
Electrical Specifications
Description
Nominal system voltage
Rated Charge Current
Max. PV Input Voltage
Self-Consumption
Temp. Compensation
Max. Terminal Size
Working Temperature
Net Weight
Parameter
12 VDC
30A
25 VDC
≤10mA
-3mV/°C/2V
10mm 8 AWG
-35°C to +45°C / -20°F to 113°F
2
0.29 kg 0.65 lb.
163.83 x 109.62 x 44.7mm
6.45 x 4.31 x 1.76in
Dimensions
IP20
RS232
Enclosure
Communication
Certification
Battery Charging Parameters
Battery
High Voltage Disconnect
Charging Limit Voltage
Equalization Voltage
SEALED
FLOODED
LI (LEP)
16 V
15.5 V
16 V
15.5 V
16 V
15.5 V
-----
14.6 V
14.8 V
----14.2 V
(User:12.6-16V)
Boost Voltage
14.2 V
14.4 V
14.6 V
Float Voltage
Boost Return Voltage
Low Voltage Reconnect
Under Voltage Recover
Under Voltage Warning
13.8 V
13.2 V
12.6 V
12.2V
13.8 V
13.2 V
12.6 V
12.2V
13.2 V
13.2 V
12.6 V
12.2V
----13.2 V
12.6 V
12.2V
12V
11.1V
12V
11.1V
12V
11.1V
12V
11.1V
10.8V
-----
10.8V
10.8V
2 hours
2 hours
10.8V
-----
2 hours
2 hours
-----
Low Voltage Disconnect
Discharging Limit Voltage
Equalization Duration
Boost Duration
13
GEL
16 V
15.5 V
2 hours
* Battery charging parameters in LI mode can be programmed using Renogy BT App.
** Default charging parameters in LI mode are programmed for 12.8V LFP battery.
Before using Wanderer to charge other types of lithium battery, set the parameters
according to the suggestions from battery manufacturer.
Dimensions
14
2775 E. Philadelphia St., Ontario, CA 91761
1-800-330-8678
Renogy reserves the right to change the contents of this manual without notice.
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