Renogy 100W Solar Suitcase w/ Voyager

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 to indicate potentially dangerous conditions or important safety information.

• [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 and follow all instructions and precautions mentioned in this user 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.

Battery Safety

• Use only sealed lead-acid, flooded, gel or lithium (LFP) 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.
• Carefully read battery manuals before operation.
• Do NOT let the positive (+) and negative (-) terminals of the battery touch each other.
• Recycle battery when it is replaced.
• 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 nonsealed / vented/ flooded / wet cell lead acid batteries.
• Do NOT equalize sealed / VRLA type AGM / Gel cell batteries UNLESS permitted by battery manufacturer.

General Information

The Renogy Solar Suitcase combines highly efficient monocrystalline solar panels with a 20A Voyager charge controller to create an easy-to-use, 'plug and play' system. This system is specifically designed for mobile off-grid applications, where space and weight limitations are abundant. The Solar Suitcase models support 12V deep cycle battery varieties such as sealed-lead acid, gel, and flooded. With built-in tilting stands, these panels can be adjusted at different angles to maximize the power output throughout the seasons.

The alligator clips included in this package make it easy to connect the panel to a battery in seconds. If one ever needs to connect a battery with a different type of end terminal, the alligator clips are attached via MC4 Connectors.

Key Features

• Easy to read LCD displaying solar charge information
• 7 Battery Type Compatible – Lithium-ion, LiFePO4, LTO, Gel, AGM, Flooded, and Calcium
• 4 Stage charging: Bulk, Boost, Float, and Equalization
• Temperature compensation and correcting the charging and discharging parameters automatically, improving battery lifetime.
• Protection against: overcharging, over-discharging, overload, short-circuit, and reverse polarity.
• Negative ground controller.
• Tilting stand for maximum solar generating potential.
• Convenient storage case for easy transportation.

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.

Four Charging Stages

A graph illustrates the charging stages over time. The Y-axis represents Voltage and the X-axis represents Time. The stages shown are: Night Charge, Bulk Charge, Boost Charge, Float Charge, and Equalize.

• 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 default time for this is 120 minutes for the Voyager.
• 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 a smaller quantity. The Voyager charge controller has a 4-stage battery charging algorithm for rapid, efficient, and safe battery charging: Bulk Charge, Boost Charge, Float Charge, and Equalization. The purpose is to offset power consumption while maintaining 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 at a Float set point and will end the float charge stage, referring back to bulk charging.
• Equalization: This stage is carried out approximately every 28 days. It is an 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] 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.

[WARNING] Over-charging and excessive gas precipitation may damage the battery plates and activate material shedding on them. Too high of an equalizing charge or for too long may cause damage. Please carefully review the specific requirements of the battery used in the system.

[WARNING] Equalization may increase battery voltage to a level damaging to sensitive DC loads. Ensure that all load allowable input voltages are greater than the equalizing charging set point volta.

Included Components

MC4 to Alligator Clips w/ Fuse

Used for connecting the charge controller to the battery. The entire cable from the charge controller to the alligator clips measures 9.9 feet and includes an inline fuse of 10A.

Optional Components

Optional components that require a separate purchase:

Remote Temperature Sensor

Measures the temperature at the battery and uses this data for very accurate temperature compensation. The sensor is supplied with a 9.9 feet cable length that connects to the charge controller.

Identification of Parts

The rear of the folded solar suitcase shows the solar panels, junction box, charge controller, tilt stands, and wiring. The Voyager charge controller's front displays a backlit LCD, buttons, and an LED bar. The rear of the charge controller shows connection terminals.

Key Parts (Solar Suitcase Assembly)

• 1. 20A Voyager Charge Controller
• 2. Junction Box
• 3. MC4 Connectors
• 4. Tilt Stands
• 5. Battery Alligator Clips
• 6. In-line fuse (10A)
• 7. Latch
• 8. Handle
• 9. Case (Not pictured)

Key Parts (Voyager Charge Controller)

• 1. Backlit LCD
• 2. AMP/VOLT Button
• 3. BATTERY TYPE Button
• 4. LED Bar
• 5. Remote Temperature Sensor Port
• 6. Battery Terminals
• 7. Solar Terminals

Installation

1. Unlatch and unfold unit then connect MC4 Connectors

Unlatch and unfold the solar suitcase. Connect the MC4 connectors from the solar panels to the charge controller's solar input terminals.

2. Connect Battery Alligator Clips to 12V Battery

Connect the red alligator clip to the positive (+) terminal of the 12V battery and the black alligator clip to the negative (-) terminal.

3. Unscrew butterfly nut tilt to desired angle and lock butterfly nut

Unscrew the butterfly nut on the tilt stand, adjust the solar panel to the desired angle, and then lock the butterfly nut. To maximize output, adjust the angle of the suitcase regularly to track the sun's movement throughout the season.

The recommended tilt angle (θ) varies by season:

• Summer: θ = Latitude – 15°
• Fall and Spring: θ = at latitude
• Winter: θ = Latitude + 15°

Operation

When the controller powers on, the Voyager will run a self-quality check mode and automatically display figures on the LCD before going into auto work. The self-check includes:

• Self-test starts, digital meter segments test
• Software version test
• Rated voltage Test
• Rated Current Test
• External battery temperature sensor test (if connected)

Selecting Battery Type

[WARNING] Incorrect battery type setting may damage your battery. Please check your battery manufacturer's specifications before selecting battery type.

The Voyager provides 7 battery types for selection: Lithium-ion, LiFePO4, LTO, Gel, AGM, Flooded, and Calcium Battery.

Press and hold the BATTERY TYPE Button for 3 seconds to enter battery selection mode. Press the BATTERY TYPE Button until the desired battery type is displayed. After a few seconds, the highlighted battery type will automatically be selected.

[NOTE] Lithium ion batteries shown in the LCD indicate different types:

• Lithium Cobalt Oxide LiCoO2 (LCO) battery
• Lithium Manganese Oxide LiMn2O4 (LMQ) battery
• Lithium Nickel Manganese Cobalt Oxide LiNiMnCoO2 (NMC) battery
• Lithium Nickel Cobalt Aluminum Oxide LiNiCoAlo2 (NCA) battery
• LiFePO4 battery indicates Lithium-iron Phosphate or LFP Battery
• LTO Battery indicates Lithium Titanate Oxidized, Li4Ti5O12 Battery

AMP/VOLT Button

Pressing the AMP/VOLT Button will sequence through the following display parameters: Battery Voltage, Charging Current, Charged Capacity (Amp-hour), and Battery Temperature (if an external temperature sensor is connected).

Normal Sequencing Display: Shows readings for Voltage (V), Current (A), Amp-hours (AH), and Temperature (°C).

[NOTE] The following is an alternative display voltage for when the battery is Fully charged: 8.8.8 V.

LED Display

The LED display shows icons for solar input (sun with panels), battery status (battery icon with a segmented bar indicating charge level), and a percentage display (e.g., 100%).

System Status Icons

LED Behavior

[NOTE] BV = Battery Voltage

LED Error Behavior

System Status Troubleshooting

Maintenance

For best controller performance, it is recommended to perform maintenance tasks occasionally.

1. Check wiring going into the charge controller. Make sure there is no wire damage or wear.
2. Tighten all terminals and inspect any loose, broken, or burnt connections.
3. Confirm LCD and LED readings are consistent.

Frequently Asked Questions

Q. Can the kit charge two or more 12V batteries connected in parallel?

A. Yes, it's possible if the batteries have the same type and capacity and are wired in parallel as a single 12V battery bank.

Q. Is there any risk that the solar kit will overcharge my battery?

A. One of the functions of the solar charge controller is to ensure that your battery is not overcharged; therefore there is no risk of overcharge.

Q. Can I extend the battery leads?

A. Yes, it's possible – please choose the same size of cable for extension. However, the longer the extension, the greater the line loss. A bigger gauge will be required for longer runs.

Q. Do I need to clean the solar panels?

A. Yes, it is recommended to clean the glass surface for better performance. Dust and dirt should first be swept off the panel surface using a soft brush. When the sweeping is complete, use a wet cloth to wipe the panel surface to remove the remaining dirt and grime.

Q. Can rain damage the solar kit?

A. The solar panels and charge controller are both fully waterproof (IP66, IP65).

Technical Specifications

Solar Panel Parameters

Charge Controller Parameters

Electrical Parameters

Mechanical Parameters

Battery Charging Parameters

Charging Stages

Charging Parameters Glossary

Equalization Voltage

Equalization voltage is a corrective over-charge of the battery. The user should consult their battery manufacturer regarding specific battery equalization capacity. This parameter sets the equalization voltage to set the battery at when it reaches the equalization state.

Boost Voltage

Users should check with their battery manufacturer for proper charging parameters. In this stage, users set the boost voltage where the battery will reach a voltage level and remain there until the battery undergoes an absorption stage.

Float Voltage

Once the charge controller recognizes the set float voltage, it will commence floating. The battery is supposed to be fully charged in this state, and the charge current is reduced to maintain battery stability levels.

State of Charge

Dimensions

Voyager

The Voyager charge controller has dimensions of approximately 34 mm (1.3 inches) in thickness, 162 mm (6.4 inches) in width, and 97 mm (3.8 inches) in height. The front panel depth is approximately 53 mm (2.1 inches), and the mounting holes are 4.0 mm (0.2 inches).

100W Suitcase

The unfolded 100W Suitcase has dimensions of approximately 1334 mm (52.5 inches) in length and 509 mm (20.0 inches) in width. The panel area itself is approximately 1260 mm (49.6 inches) in length.

Contact Information

Renogy

• US: 2775 E Philadelphia St, Ontario, CA 91761, USA. Phone: 909-287-7111. Website: www.renogy.com. Email: customerservice@renogy.com.
• CN: Suzhou High-tech Zone, Peiyuan Road No. 1, Building 5, Floor 4. Phone: 400-6636-695. Website: https://www.renogy.cn. Email: sales@renogy.cn.
• JP: Website: https://www.renogy.jp. Email: onlinestorejp@renogy.com.
• CA: Website: https://ca.renogy.com. Email: onlinestoreca@renogy.com.
• AU: Website: https://au.renogy.com. Email: onlinestoreau@renogy.com.
• UK: Website: https://uk.renogy.com. Email: onlinestoreuk@renogy.com.
• DE: Website: https://de.renogy.com. Email: onlinestorede@renogy.com.
• FR: Website: https://fr.renogy.com. Email: onlinestorefr@renogy.com.

Renogy reserves the right to change the contents of this manual without notice.