Renogy RCC20VOYP-G1 User manual

Renogy RCC20VOYP-G1 User manual
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VOYAGER
Version 1.0
FEES eT
VOYAGER
SOLAR CHARGE CONTROLLER
01
/À\ 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:
Indicates a potentially dangerous condition. Use extreme
caution when performing this task
Indicates a critical procedure for safe and proper operation of
the controller
Indicates a procedure or function that is important to the safe
and proper operation of the controller
IN General Safety Information
e Read all 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.
EN 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 PV input voltage does not exceed 55V 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.
EN Battery Safety
Lead-acid and LiFePO4 batteries can be dangerous. Ensure no sparks or
flames are present when working near batteries. Refer to battery
manufacturer's specific charging rate setting. Do NOT charge improper
battery type.
Never attempt to charge a damaged battery, frozen battery, or
non-rechargeable battery.
Do NOT let the positive (+) and negative (-) terminals of the battery touch
each other.
Use only sealed lead-acid, flooded, gel or LiFePO4 batteries that 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.
If battery acid contacts skin or clothing, wash immediately with soap and
water. If acid enters eye, immediately flush eye running with cold water for
at least 10 minutes and get medical attention immediately.
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.
03
Table of Contents
General Information
Dimensions
Optional Component
Installation
Mounting Recommendations
Wiring
Wire AWG
Operation
Change the Parameters
1. Clear overall power generation to 0 KWh
2. Selecting Battery Type
3. Change from C* to F*
4. Select Lithium Battery Voltage and Charge Voltage
System Status Icons
Four Charging Stages
Troubleshooting
Maintenance
Technical Specifications
04
05
05
06
06
06
07
07
08
08
08
08
09
09
General Information
The Voyager is an advanced PWM charge controller suitable for 12/24VV solar
system applications. It features an intuitive LCD displaying information such as
charging current and battery voltage, as well as an error code system to quickly
diagnose potential faults. The Voyager is completely waterproof and suitable for
charging up to 4 different battery types, including Lithium.
Key Features
e Smart PWM technology, high efficiency with reawakening Lithium feature
e Backlit LCD displaying system operating information and error codes
e 4 Battery Type Compatible — Gel, AGM, Flooded, Lithium
e Waterproof design, suitable for indoor or outdoor use
e 4-Stage PWM Charging: Bulk, Absorption, Float, & Equalization
e Protections: Multiple Battery, Controller, and PV electronic protections
e Common positive charge controller
Ш Identification of Parts
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VOYAGER
SOLAR CHARGE CONTROLLER
12/24 VOLT
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Optional Component
The Voyager is shipped by itself with no additional components. Optional
components that require a separate purchase:
Voyager Temperature Sensor: Measures
the temperature at the battery and uses this data
for very accurate temperature compensation. The
sensor is supplied with a 9.8ft cable length that
connects to the charge controller. Simply connect
the cable and adhere the sensor on top or the side
of the battery to record ambient temperature
around the battery.
Installation
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.
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:
Never install the controller in a sealed enclosure with flooded
batteries. Gas can accumulate and there is a risk of explosion.
The Voyager is designed for vertical mounting on a wall.
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
5. Secure the charge controller (Back)
E Wiring
The Voyager has 4 terminals which are
clearly labeled as “solar” or “battery”.
0A FUSE/ 10AVOYP
20A FUSE/ 20AVOYP
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This assumes one 100W panel. The fuse before the charge controller
Will change depending on the number of solar panels connected.
H Cable Sizing
Cable Size (AWG) 14-12AWG | 12-10AWG
NEC Maximum Current for different Copper Wire Sizes
AWG | 16 ; 14:12: 101 8: 6:41 2 0
Max.
MX 1 10A : 15A: 20A! 30A: 55A; 75A: 95A | 130A; 170A
The solar controller should be installed as near the battery as
possible to avoid efficiency loss.
When the connections are completed correctly, the solar
controller will turn on and begin working automatically.
After connecting the battery to the charge controller, the controller will turn on
automatically. Assuming normal operation, the charge controller will cycle
through different display. They are as follows:
Parameter | Display
PV Array Voltage = 0.0"
4
| Charging Current = 0.0% |
y
| Generated Energy =" 0.0" |
y
| Battery Voltage =" 0.0" |
4
| Temperature e” 0.0" |
The Voyager is an easy to use controller requiring minimal maintenance. The user can
adjust some parameters based on the display screen. The user can manually cycle
through the display screens by using the"AMP/VOLT" and "BATTERY TYPE" buttons
(С) AMP VOLT : Cycles forwards through the different display screens.
BATTERY Cycles backwards through the different select screens
e TYPE Customize some parameters on the charge controller
Change the Parameters
The screen must be at the appropriate interface in order to
change the specific parameter.
1. Clear overall power generation to 0 KWh
The user can cycle to the KWh screen by pressing "BATTERY TYPE" or
"AMP/VOLT" and in order to reset the current power generation back to 0
kWh the user must hold down "BATTERY TYPE"
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2. Selecting Battery Type
Incorrect battery type setting may damage your battery. Please check
your battery manufacturer's specifications to when selecting battery type.
If selecting Lithium and wanting to set Battery Voltage or Charge
Parameters, go to “4. Select lithium Battery Voltage and Charge
Voltage,” later in this table.
SEL is referring to Sealed and AGM battery
In the screen showing the battery voltage, hold down "BATTERY TYPE" for
approximately 3-5 seconds before the screen flashes the current battery type.
Once flashing, use the "AMP/VOLT" button to select the proper battery type and
then hold down "BATTERY TYPE" again to lock in the selected battery type.
E-SEL E-LEL E-FLd E= LI
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3. Change from C° to F°
In the screen showing the temperature of the controller or remote
temperature sensor, the user can hold down the "BATTERY TYPE" button
for approximately 3-5 seconds to switch from Celsius to Fahrenheit or vice
versa. | ur ce “ | - | a 7 2
|
4. Select Lithium Battery Voltage and Charge Voltage
In the screen showing the battery voltage, hold down
"BATTERY TYPE" for approximately 3-5 seconds = т I 1
before the screen flashes the current battery type. Once ve ML |
flashing, use the"AMP/VOLT" button to highlight LI.
Once Llis flashing, tap the "BATTERY TYPE" = | =
button and a 12V will flash in the screen. = Lv
If you want 12V LI charging, then select the "BATTERY TYPE" again to move to LI
Boost Charging Voltage. If you want a 24V LI charging, then you select
"AMP/VOLT"to move from 12V to 24V LI Charging. Once you confirm your LI
Charging (12V or 24V) press "BATTERY TYPE" to move to LI Boost Charging
Voltage. ë T _| = сне
mm BATT. Nd 12V
= 1 1.Cv
Press “AMP/VOLT” to change the Boost Voltage. The default setting is 14.2V
and the user can set it in the range 12.6-16.0V, in 0.2V increments. Once
done, hold “BATTERY TYPE” to confirm the selection. The setting will also be
automatically save after 15 seconds without holding “BATTERY TYPE”.
Please note if choosing a 24V LI battery setting, the boost
charging voltages will still be shown in their 12V values. Multiply
the value by 2 to find out 24V charging voltage.
System Status Icons
Behavior
Constant: System is normal, but it is not charging
Charging: The bars will be sequencing indicating the system is charging.
Constant: The battery is at full charge.
Flashing: The battery is overvoltage.
> mm | OU Г
Flashing: The battery is under voltage.
Flashing: The bars are sequencing, indicating the
controller is activating over-discharged lithium battery.
:
Ш)
C | и Constant: System error.
Four Charging Stages
The Voyager 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.
PWM Technology
The Voyager 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.
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. If 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. 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.
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.
E Lithum Battery Activation
The Voyager PWM charge controller has a reactivation feature to awaken a
sleeping lithium battery. The protection circuit of Li-ion battery will typically turn
the battery off and make it unusable if over-discharged. This can happen when
storing a Li-ion 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 activate and charge batteries, these batteries would become
unserviceable and the packs would be discarded. The Voyager 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.
When using the Voyager to charge a 24V lithium battery bank, set the system
voltage to 24V instead of auto recognition. Otherwise, the over-discharged 24V
lithium battery will not be activated.
Incorrect battery type setting may damage your battery.
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.
Troubleshooting
Indicator Description
Troubleshoot
Use a multi-meter to check the voltage of
Other Considerations
Charge controller does not
charge during daytime when
the sun is shining on the solar
panels.
Е Battery the battery. Make sure the battery voltage
Flashin over voltage is not exceeding the rated specification of
ashing the charge controller. Disconnect battery.
Use a multi-meter to verify the rated battery
Battery .
| over voltage voltage. Disconnect any loads connected
Flashing to the battery to allow it to charge.
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 has been reversed
on the charge controller's solar terminals.
Everything is connected
correctly, but the LCD on the
controller does not turn on
Check the rated battery voltage. The LCD will
not display on the charge controller unless there
is at least 9V coming from the battery bank.
H Error Codes
Error Number Description
EO No error detected
E01 Battery over-discharged
E02 Battery over-voltage
E06 Controller over-temperature
E07 Battery over-temperature
E08 PV input over-current
E10 PV over-voltage
E13 PV reverse polarity
E14 Battery reverse polarity
E15 No Battery Detected
For best controller performance, it is recommended that these tasks be
performed from time to time.
1.Check wiring going into the charge controller and make sure there is no wire damage
or wear.
2. Tighten all terminals and inspect any loose, broken, or burnt up connections
3.Occasionally clean the case using a damp cloth
Technical Specifications
Electrical Parameters VOYP10 VOYP20
System Voltage 12V/24V Auto
Battery Rated Current 10A | 20A
Max Battery Voltage 32V
PV Input Voltage Range 15V-55V
[email protected]
Max PV Input (Voc) [email protected]
12V @ 130W 12V @ 260W
Max Power Input 24V @ 260W 24V @ 520W
. 12V @ 0.22W 12V @ 0.24W
Power Consumption 24V a 0.72W 24V e 0.74W
Battery Types SLD/AGM, GEL, FLD, LI
Battery / Controller Over-Temperature Protection
PV / Battery Reverse Polarity, Over-Voltage,
Over-Current Protection
Electronic Protections
Mechanical Parameters
Grounding Type Positive
Controller Terminals 20-6 AWG, 2-pin terminals
Temperature Compensation -3mV/C/2V, excludes LI
Operating Temperature -31°F ~113F
Storage Temperature -31°F ~ 167°F
Operating / Storage Humidity | 10% ~ 90%, No Condensation
Protection Level IP67
Dimensions 6.08 x 3.83 x 1.40 in
Weight 0.55 Ibs
Battery Charging GEL | SEALED |FLOODED| LITHIUM
Parameters
High Voltage Disconnect 16 V
Charging Limit Voltage 15.5V | 15.5V 15.5 V 15.5V
Over Voltage Reconnect 15V 15V 15 V 15 V
Equalization Voltage — 14.6V 14.8V —
Boost Voltage 14.2V | 14.4 V | 14.6 V (User 12.8. 16V
Float Voltage 13.8V | 13.8V | 13.8V —
Boost Return Voltage 13.2V
Low Voltage Reconnect 12.6 V
Under Voltage Recover 12.2 V
Under Voltage Warning 12 V
Low Voltage Disconnect 11.1 \
Discharging Limit Voltage 10.8 V
Equalization Duration — | 2 hours | 2 hours | —
Low Voltage Reconnect 2 hours | 2 hours | 2 hours | —
AB
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