Renogy Wanderer PWM Solar Charge Controller

Identification of Parts

The Wanderer charge controller features the following key parts:

• 1. LCD Screen: Displays system operation, parameters, and error codes.
• 2. Select Button: Cycles forward through the LCD screens.
• 3. Enter Button: Turns on the Load Circuit in Manual Load Mode; Long press to enter Setting Mode.
• 4. USB Ports: Integrated 5V, up to 2Amp USB for mobile or portable device charging.
• 5. Load Terminals: For connecting DC devices.
• 6. Battery Terminals: For connecting the battery.
• 7. PV Terminals: For connecting the solar panel array.
• 8. RS232 Communication Port (reserved): For future communication capabilities.

Dimensions

The physical dimensions of the Wanderer charge controller are:

• Width: 4.685 inches (119mm)
• Height: 2.953 inches (75mm)
• Depth: 2.421 inches (61.50mm)
• Mounting Hole Diameter: 0.063 inches (R1.60mm)
• Mounting Hole Spacing (Vertical): 1.083 inches (27.50mm)
• Mounting Hole Spacing (Horizontal): 0.531 inches (13.50mm)

The dimensions have a ±0.5mm tolerance.

General Installation Instructions

WARNING: Connect the battery to the charge controller BEFORE connecting the solar panel(s), unless using a solar suitcase with controller exception. The controller needs a stable power source to operate.

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 maximum wire sizes and amperage ratings for the controller.

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. Ensure good ventilation.
2. Check for Clearance: Verify sufficient room to run wires and adequate clearance above and below the controller for ventilation. The clearance should be at least 6 inches (150mm).
3. Mark Holes: Mark the mounting hole positions.
4. Drill Holes: Drill the mounting holes.
5. Secure the charge controller: Mount the controller securely.

Ventilation Diagram: The controller requires adequate airflow. Arrows indicate warm air exiting from the top and cool air entering from the bottom, with a recommended clearance of 6 inches (150mm) on both sides.

Wiring and Fusing

The wire terminals are closed by default. Use bare wiring when connecting to the Wanderer's terminal blocks. Ensure the terminal hatch is completely open before the first-time use.

1. Rotate the hatch counterclockwise (CCW) to the open position to expose the wire hatch.
2. Insert bare wire into the terminal for the respective connection.
3. Rotate clockwise (CW) until the hatch has closed and clamped onto the wire.

Terminal Block States:

• Open Terminal Block: Shows terminals ready for wire insertion.
• Closed Terminal Block: Shows terminals with wires secured.

Wire Sizing and Fusing Recommendations:

The recommended fuse and cable gauge depend on the PV Array wiring and battery size, based on the actual amps flowing through the cable. The following charts account for less than 3% voltage drop.

*Panel connection assumes series to meet 24V system minimum setup.

Larger wire sizes generally improve performance, whereas smaller wire sizes may reduce performance, especially if undersized. When considering wiring, fusing, and connection options, opt for heavier components and shorter wire lengths for less resistance and voltage drop. Terminal Size Limitations may apply.

Fusing: Fusing is recommended in PV systems for safety. Use the recommended wire gauge size based on the PV system and the controller.

Fuse from Controller to Battery: Controller to Battery Fuse = Current Rating of Charge Controller (e.g., Wanderer 10 = 10A fuse).

Fuse from Solar Panel(s) to Controller: For example, 200W with 2 x 100W panels in parallel, Total Amperage = Isc1 + Isc2 = (5.75A + 5.75A) * 1.2. Fuse = minimum of 11.5 * 1.2 = 14.38A, so a 15A fuse is recommended.

Battery Wiring

WARNING: Connect the battery to the charge controller BEFORE connecting the solar panel(s), unless using a solar suitcase with controller exception. The controller needs a stable power source to operate.

1. Step 1: [Screwdriver turning counterclockwise] on the positive terminal.
2. Step 2: [Screwdriver turning clockwise] on the positive terminal, securing the wire.
3. Step 3: [Screwdriver turning counterclockwise] on the negative terminal.
4. Step 4: [Screwdriver turning clockwise] on the negative terminal, securing the wire with a checkmark [✓].

PV Wiring

1. Step 1: [Screwdriver turning counterclockwise] on the positive PV terminal.
2. Step 2: [Screwdriver turning clockwise] on the positive PV terminal, securing the wire.
3. Step 3: [Screwdriver turning counterclockwise] on the negative PV terminal.
4. Step 4: [Screwdriver turning clockwise] on the negative PV terminal, securing the wire with a checkmark [✓].

Load Wiring (Optional)

1. Step 1: [Screwdriver turning counterclockwise] on the positive load terminal.
2. Step 2: [Screwdriver turning clockwise] on the positive load terminal, securing the wire with a checkmark [✓].
3. Step 3: [Screwdriver turning counterclockwise] on the negative load terminal.
4. Step 4: [Screwdriver turning clockwise] on the negative load terminal, securing the wire with a checkmark [✓].

Communication Wiring (Optional)

1. Step 1: Connect communication wires.
2. Step 2: [Checkmark ✓] indicating successful connection.

Auto Recognition

The Wanderer controller automatically detects the battery voltage for Non-Lithium 12V or 24V batteries. Lithium batteries require manual programming found in the Settings menu.

Main Display

The controller cycles through various display screens:

• Main Screen: Shows battery voltage (e.g., BATT 12.3V).
• Solar Panel Voltage: Shows PV voltage (e.g., PV 12.0V).
• Charging Current: Shows current flow (e.g., 0.0A).
• Error Code: Displays error codes (e.g., E0).
• Battery Voltage: Shows battery voltage (e.g., BATT 12.3V).
• Load Mode: Shows load status (e.g., LOAD 15).
• Load Current: Shows load current (e.g., LOAD 0.0A).

LCD Overview

The LCD screen displays information about the Port, Parameter Value, Battery type, Amps/Volts, and System Voltage. The status of the Solar Panel, Battery, and Load is indicated by icons:

Four Charging Stages

The Wanderer features a 4-stage battery charging algorithm for rapid, efficient, and safe charging:

1. Bulk Charge: Uses 100% of available solar power for constant current charging.
2. Boost Charge: An absorption stage with constant voltage regulation to prevent heating and gassing. Boost time is 120 minutes.
3. Float Charge: Reduces battery voltage to a float set point. Once fully charged, charge current converts to heat or gas; the controller reduces voltage for light charging to offset power consumption and maintain capacity. If load exceeds charge current, the controller returns to Bulk charging.
4. Equalization: Carried out approximately every 28 days. It involves intentional overcharging for a controlled period to stir electrolyte, balance voltage, and complete chemical reactions, increasing voltage and gasifying the electrolyte.

WARNING: Equalization will not exit until adequate charging current is available from the solar panel. There should be NO load on the batteries during equalization.

Over-charging or prolonged equalization can damage battery plates. Always review specific battery requirements.

Set the Battery Type

Non-Lithium Batteries:

1. Navigate to the Battery Voltage Screen.
2. Hold ENTER for approximately 3 seconds until the battery type begins to flash.
3. Tap SELECT to highlight the desired battery type.
4. To confirm, hold ENTER for 3 seconds.

Lithium Batteries:

1. Press SELECT until the Battery Voltage Screen is highlighted.
2. Hold ENTER for approximately 3 seconds until the battery type starts to flash.
3. Tap SELECT to highlight 'Lithium', then tap ENTER to confirm.
4. Tap SELECT to highlight the nominal battery voltage (12V or 24V), then tap ENTER to confirm.
5. Tap SELECT to choose your charging voltage setpoint (in 0.2V increments).
6. To confirm, hold ENTER for 3 seconds to save Lithium, Battery Voltage, and Charge Voltage settings.

Battery Type Display Examples:

• Sealed (SLD)
• Gel (GEL)
• Flooded (FLd)
• Lithium (LI)

System Voltage Display Examples: 12V, 24V, 14.2V (charging voltage).

Load Terminal

WARNING: Ensure the load is compatible with the battery type of the system. 12V loads damaged in 24V battery systems will not be covered in warranty.

The Load Terminal allows direct connection of DC devices with optional timer functions. It is powered by the battery, so voltages present on the battery will be seen at the Load Terminal. The terminal limits are set by the controller to a maximum of 10Amps. For 24V battery banks, a 24V DC Load Terminal is also available. It is recommended to use simple electronics like lights and fans that have no issues with on/off cycling.

Programming the Load Terminal:

Press SELECT until the Load Mode Screen is highlighted, showing a numerical load mode. The chart below describes the load terminal settings:

Setting Load Mode:

1. Highlight the Load Mode Screen.
2. Hold ENTER for approximately 3 seconds until the Load Mode starts to flash.
3. Tap SELECT to highlight your desired Load Mode.
4. To confirm, hold ENTER for 3 seconds.

Programs 0, 1-14, 16, and 17 are automatic. Program 15 requires manual user toggling via the ENTER button to observe the Light Bulb Brightness icon confirming the load is activated.

Error Codes

If the controller is not functioning correctly, it may display an error message due to internal electronic protection. Error messages stop normal operation and clear when resolved. This is not indicative of a defective controller but may require troubleshooting.