Renogy Wanderer 30A PWM Charge Controller Manual
This manual covers the Renogy Wanderer 30A PWM Charge Controller, designed for 12V battery banks in off-grid solar applications.
Important Safety Instructions
Please save these instructions.
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 25 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.
Battery Safety
- Do NOT let the positive (+) and negative (-) terminals of the battery touch each other.
- Use only sealed lead-acid, flooded, or gel 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.
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.
General Information
The Wanderer is an advanced charge controller for off-grid solar applications. Integrating highly efficient PWM charging, this controller increases battery life and improved system performance. It is exclusively designed for 12V battery banks. The controller is embedded with self-diagnostics and electronic protection functions that prevent damages from installation mistakes or system faults.
Key Features
- Optimized for 12 VDC system voltage
- 30A charging capacity
- Deep Cycle Sealed, Gel, and Flooded battery option ?
- 4 Stage PWM charging: Bulk, Boost, Float, and Equalization
- Temperature compensation and correcting the charging and discharging parameters automatically, improving battery lifetime.
- Protection against: overcharging, short-circuit, and reverse polarity.
- Negative ground controller
- Remote temperature compensation compatible (accessory sold separately)
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.
Charging Stages
A graph illustrates the charging stages over time, showing voltage levels.
- 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: 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 equalizing charge or for too long may cause damage.
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.
Identification of Parts
The Wanderer charge controller features several indicators and terminals:
- 1. Battery Select Button: Used to select the battery type.
- 2. Battery Select Indicator: Shows the selected battery type (Sealed, Gel, Flooded).
- 3. Battery Indicator: Displays battery status.
- 4. PV Indicator: Displays solar panel status.
- 5. Remote Temperature Sensor Adapter: Port for the optional TS-R sensor.
- 6. PV Terminals: Connections for the solar panel array (+/-).
- 7. Battery Terminals: Connections for the battery bank (+/-).
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.
CAUTION: 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.
- Choose Mounting Location: Place the controller on a vertical surface protected from direct sunlight, high temperatures, and water. Make sure there is good ventilation.
- 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).
- Mark Holes
- Drill Holes
NOTE: The Wanderer is not equipped with screws for wall mounting.
- Secure the charge controller.
Wiring
1. Unscrew battery terminals and connect battery connections:
Illustrations show using a screwdriver to loosen terminals, inserting battery wires (positive and negative), and tightening the terminals. A checkmark ✔️ indicates correct connection.
2. Unscrew PV terminals and connect PV connections:
Illustrations show using a screwdriver to loosen PV terminals, inserting solar panel wires (positive and negative), and tightening the terminals. A checkmark ✔️ indicates correct connection.
3. Insert temperature sensor block terminal and connect wires (POLARITY SENSITIVITY DOES NOT MATTER):
An illustration shows the temperature sensor connector being plugged into its port on the charge controller. A checkmark ✔️ indicates correct connection.
Operation
After connecting the battery to the charge controller, the controller will turn on automatically. Users set the battery type, and the controller handles the rest.
Setting Battery Type
Hold the gray button for approximately 7 seconds until the LED flashes. Press the gray button again to cycle through battery types (Sealed, Gel, Flooded), indicated by color. Leave the controller undisturbed for about 10 seconds to set the parameter.
NOTE: If the LED lights do not flash, hold the gray button for 7 seconds, release, and immediately press it again to enable flashing.
Battery types are indicated by color: Green for Sealed, Orange for Gel, and Red for Flooded.
LED Indicators
The Wanderer provides status information via LED indicators on the PV and Battery terminals. The following chart details these indicators:
| PV Indicator | BATT Indicator | Controller Status |
|---|---|---|
| Fast Flashing | n/a | PV terminal is over-voltage |
| Solid | n/a | PV terminal low output |
| Slow Flashing | Solid | Battery is charging normally |
| 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 | The battery is over-heating |
System Status Troubleshooting
| Description | Troubleshoot |
|---|---|
| Battery is low-voltage | 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 | |
| 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.
- Check that controller is mounted in a clean, dry, and ventilated area.
- Check wiring going into the charge controller and make sure there is no wire damage or wear.
- Tighten all terminals and inspect any loose, broken, or burnt up connections.
Fusing
Fusing is a recommendation in PV systems to provide a safety measure for connections going from panel to controller and controller to battery. Remember to always use the recommended wire gauge size based on the PV system and the controller.
NEC Maximum Current for different Copper Wire Sizes
| AWG | 16 | 14 | 12 | 10 | 8 | 6 | 4 | 2 | 0 |
|---|---|---|---|---|---|---|---|---|---|
| Max. Current | 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
Technical Specifications
Electrical Specifications
| Description | Parameter |
|---|---|
| Nominal Voltage | 12 VDC |
| Rated Charge Current | 30A |
| Max. PV Input Voltage | 25 VDC |
| Self-Consumption | <10mA |
| High Voltage Disconnect | 16V |
| Over-Voltage Reconnect | 15V |
| Under Voltage Warning | 12V |
| Charging Limit Voltage | ≤15V |
| Equalization Voltage | Sealed:14.6V; Flooded: 14.8V; Gel: NO |
| Boost Voltage | Sealed: 14.4V; Flooded: 14.6V; Gel: 14.2V |
| Float Voltage | 13.8V |
| Equalize Duration | 120 min |
| Boost Duration | 120 min |
Battery Charging Parameters
| Battery | GEL | SEALED | FLOODED |
|---|---|---|---|
| High Voltage Disconnect | 16 V | 16 V | 16 V |
| Charging Limit Voltage | 15.5 V | 15.5 V | 15.5 V |
| Over Voltage Reconnect | 15 V | 15 V | 15 V |
| Equalization Voltage | ---- | 14.6 V | 15.5 V |
| Boost Voltage | 14.2 V | 14.4 V | 14.8 V |
| Float Voltage | 13.8 V | 13.8 V | 13.2 V |
| Boost Return Voltage | 13.2 V | 13.2 V | 13.2 V |
| Under Voltage Warning | 12 V | 12 V | 12 V |
| Equalization Duration | ---- | 2 hours | 2 hours |
| Boost Duration | 2 hours | 2 hours | 2 hours |
Mechanical Specification
| Description | Parameter |
|---|---|
| Temperature Compensation | -3mV/°C/2V |
| Working Temperature | -30°C-45°C / -20°F-113°F |
| Storage Temperature | -35°C-80°C / -31°F—176°F |
| Max Gauge Size | Up to #8AWG |
| Weight | 0.29 kg / 0.65 lbs. |
| Dimensions | 163.83 x 109.62 x 44.7mm 6.45 x 4.31 x 1.76in |
| Enclosure | IP20 |
Dimensions
Technical drawings show the dimensions of the Wanderer charge controller in millimeters and inches from various views.
