Renogy Rover 40A User manual

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Rover Series
Rover 20A | 40A
Maximum Power Point Tracking Solar Charge Controller
2775 E. Philadelphia St., Ontario, CA 91761
1-800-330-8678
Version 1.0

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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 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.
Do NOT allow water to enter the controller.
Make sure all connections going into and from the controller are tight.
Charge Controller Safety
NEVER connect the solar panel array to the controller without a battery. Battery
must be connected first.
Ensure input voltage does not exceed 100 VDC to prevent permanent damage.
Use the Open Circuit (Voc) to make sure the voltage does not exceed this value
when connecting panels together.
Do not exceed 20A (ROV-20) or 40A (ROV-40). The Short Circuit (Isc) of the solar
array should be less than 20A (ROV-20) or 40A (ROV-40).
Battery Safety
Use only sealed lead-acid, flooded, or gel batteries which must be deep cycle.

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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 non-sealed / vented/ flooded / wet cell lead acid
batteries.
Do NOT equalize sealed / VRLA type AGM / Gel cell batteries UNLESS permitted
by 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.
WARNING: Do NOT connect any inverters or battery charger into the load terminal
of the charge controller.
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.

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Table of Contents
General Information..................................................................................4
Additional Components ...........................................................................7
Identification of Parts...............................................................................8
Operation.................................................................................................13
LED Indicators ........................................................................................17
Rover Protections...................................................................................19
System Status Troubleshooting............................................................20
Maintenance............................................................................................21
Fusing......................................................................................................21
Technical Specifications........................................................................22
Electrical Parameters ..........................................................................22
Battery Charging Parameters .............................................................22
Mechanical Parameters.......................................................................23
ROVER: PV Power –Conversion Efficiency Curves ............................24
Dimensions .............................................................................................25

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General Information
The Rover Series charge controllers are suitable for various off-grid solar applications. It
protects the battery from being over-charged by the solar modules and over-discharged
by the loads.The controller features a smart tracking algorithm that maximizes the energy
from the solar PV module(s) and charge the battery. At the same time, the low voltage
disconnect function (LVD) will prevent the battery from over discharging.
The Rover’s charging process has been optimized for long battery life and improved
system performance. The comprehensive self-diagnostics and electronic protection
functions can prevent damage from installation mistakes or system faults.
Key Features
Automatically detect 12V or 24V DC system voltages
Innovative MPPT technology with high tracking efficiency up to 99% and peak
conversion efficiency of 97%
Deep cycle Sealed, Gel, and Flooded battery option ready
Electronic protection: Overcharging, over-discharging, overload, and short circuit
Reverse protection: Any combination of solar module and battery, without causing
damage to any component
Customizable charging voltages
MPPT Technology
The MPPT Charge Controller utilizes Maximum Power Point Tracking technology to
extract maximum power from the solar module(s). The tracking algorithm is fully
automatic and does not require user adjustment. MPPT technology will track the array’s
maximum power point voltage (Vmp) as it varies with weather conditions, ensuring that the
maximum power is harvested from the array throughout the course of the day.
Current Boost
In many cases, the MPPT charge controller will “boost” up the current in the solar system.
The current does not come out of thin air. Instead, the power generated in the solarpanels
is the same power that is transmitted into the battery bank. Power is the product of Voltage
(V) x Amperage (A).

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Therefore, assuming 100% efficiency:
Power In = Power Out
Volts In * Amps In = Volts out * Amps out
Although MPPT controllers are not 100% efficient, they are very close at about 92-95%
efficient. Therefore, when the user has a solar system whose Vmp is greater than the
battery bank voltage, then that potential difference is proportional to the current boost.
The voltage generated at the solar module needs to be stepped down to a rate that could
charge the battery in a stable fashion by which the amperage is boosted accordingly to
the drop. It is entirely possible to have a solar module generate 8 amps going into the
charge controller and likewise have the charge controller send 10 amps to the battery
bank. This is the essence of the MPPT charge controllers and their advantage over
traditional charge controllers. In traditional charge controllers, that stepped down voltage
amount is wasted because the controller algorithm can only dissipate it as heat. The
following demonstrates a graphical point regarding the output of MPPT technology.
Limiting Effectiveness
Temperature is a huge enemy of solar modules. As the environmental temperature
increases, the operating voltage (Vmp) is reduced and limits the power generation of the
solar module. Despite the effectiveness of MPPT technology, the charging algorithm will
possibly not have much to work with and therefore there is an inevitable decrease in
performance. In this scenario, it would be preferred to have modules with higher nominal
voltage, so that despite the drop in performance of the panel, the battery is still receiving
a current boost because of the proportional drop in module voltage.
Typical Battery
Voltage Range
Maximum
Power Point
Traditional
Controller
Operating
Range
Maximum
Power Point
Current vs. Voltage (12V System)
Output Power (12V System)

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Four Charging Stages
The Rover MPPT charge controller 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*.
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. In this stage the
battery voltage has not yet reached constant voltage (Equalize or Boost), the controller
operates in constant current mode, delivering its maximum current to the batteries (MPPT
Charging)
Constant Charging: When the battery reaches the constant voltage set point, the
controller will start to operate in constant charging mode, where it is no longer MPPT
charging. The current will drop gradually. This has two stages, equalize and boost and
they are not carried out constantly in a full charge process to avoid too much gas
precipitation or overheating of the battery.
Boost Charge: Boost stage maintains a charge for 2 hours by default. The user
can adjust the constant time and preset value of boost per their demand.
Float Charge: After the constant voltage stage, the controller will reduce the battery
voltage to a float voltage set point. Once the battery is fully charged, there will be no more

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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. 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 voltage.
Additional Components
Additional components included in the package:
Remote Temperature Sensor: This sensor measures the
temperature at the battery and uses this data for very accurate
temperature compensation. Accurate temperature compensation is
important in ensuring proper battery charging regardless of the
temperature.

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USB to RS-232 Converter Cable: This PC communication cable is
needed for remote monitoring using an optional PC software.
Through the software, users could customize their charge
parameters and other settings. Download the PC software through
Renogy’s website under the “Downloads” section.
NOTE: PC Communication requires the USB be connected at all times.
Wireless capability not available.
WARNING: Do NOT use a PC Ethernet cable. This can and will cause
permanent damage to a computer.
Identification of Parts
Figure 1
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3
○
4
○
9
○
10
○
11
○
12
○
6
○
5
○
2
○
1
○
7
○
8

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Installation
Recommended tools to have before installation:
Flathead Screwdriver
Multi-Meter
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.
WARNING: Do NOT connect any inverters or battery chargers into the LOAD
TERMINAL of the charge controller
Key Parts
1. PV LED Indicator
2. Battery LED Indicator
3. Load LED Indicator
4. System Error LED Indicator
5. LCD Screen
6. Operating Keys
7. Mounting Holes
8. Remote Temperature Sensor Port (optional accessory)
9. PV Terminals
10. Battery Terminals
11. Load Terminals
12. RS-232 Port (optional accessory)

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INVERTER
BATTERY
CHARGER
HIGH AMP
DRAWING DEVICE
CAUTION: Do not 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.
You are now ready to begin connecting your battery to your charge controller.
Battery
1
2

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Load (optional)
Solar Panels
3
1
2
2
1

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PC communication (optional)
Temperature Sensor (optional, not polarity sensitive)
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).
2
1
1
2

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3. Mark Holes
4. Drill Holes
5. Secure the charge controller.
Operation
Rover is very simple to use. Simply connect the batteries, and the controller will
automatically determine the battery voltage. The controller comes equipped with an LCD
screen and 4 buttons to maneuver though the menus.
Startup Interface

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Main Display
Charging Current
Main Screen
Solar Panel Voltage
Error Code
Battery Voltage
Battery Capacity
Load Current
Accumulated AH
Load mode
Discharged AH
Ambient Temperature

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Page Up/ Increase parameter value
Page Down/ Decrease parameter value
Return to the previous menu
Enter sub menu/ save parameter value/
turn load on or off in manual mode
Programming Parameters
After entering the programming interface, press the Enter button to switch between
parameters. To change the parameters, press the Up or Down button. To save the
parameter press and hold the Enter button.
/ 
/ -

ENTER/ 
Battery type
System voltage
Equalizing voltage
Boost voltage
Over-discharge voltage
Over-discharge return voltage
Float voltage

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Programming Load Terminal
1. This screen is displaying the current Load Mode.
2. To enter screen 2 press and hold the Enter button. This screen will allow you to
change the load mode.
3. To change the load mode press the up or down button.
4. Once you have selected the desired load mode press the Enter button to save
the setting.
5. To exit the programming setting press the left button.
Load Mode Options
Setting
Mode
Description
0
Automatic(On/Off)
The load will turn on at night when the solar
panel is no longer producing any power after
a short time delay. The load will turn off when
the panel starts producing power.
1-14
Time control
When the panel is no longer producing power
the load will be ON for 1-14 hours or until the
panel starts producing power.
15
Manual
In this mode, the user can turn the Load
On/Off by pressing the Enter button at any
time.
16
Test
Used to troubleshoot load terminal (No Time
Delay). When voltage is detected load will be
off and when no voltage is detected load will
be on.
17
24Hr
The load will be on for 24 hours a day.
1
2
3
4
5

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LCD Indicators
LED Indicators
○
1---PV array
indicator
Indicating the controller's current
charging mode.
○
2---BAT indicator
Indicating the battery's current
state.
○
3---LOAD indicator
Indicating the loads' On/ Off state.
○
4---ERROR
indicator
Indicating whether the controller is
functioning normally.
1
2
3
4

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PV Indicator (1)
Status
White Solid
The PV system is charging the battery bank
White Slow
Flashing
The Controller is undergoing boost stage
White
Single
Flashing
The Controller is undergoing float stage
White Fast
Flashing
The Controller is undergoing equalization stage
White
Double
Flashing
The PV system is charging the battery bank at a slow rate.
Make sure panels are not shaded. Low Amperage
Off
The PV system is not charging the battery bank. PV not
detected.
BATT Indicator (2)
Status
White Solid
Battery is normal
White Slow
Flashing
Battery over-discharged
White Fast
Flashing
Battery over-voltage
LOAD Indicator (3)
Status
White Solid
Load is on
White Fast
Flashing
Load is over-loaded or short-circuited
Off
Load is off
Error Indicator (4)
Status
White Solid
System Error. Please check LCD for Error code
Off
System is operating normally

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Rover Protections
Protection
Behavior
PV Array Short
Circuit
When PV shot circuit occurs, the controller will stop charging.
Clear it to resume normal operation
PV Overvoltage
If the PV voltage is larger than maximum input open voltage
100VDC, PV will remain disconnected until the voltage drops
below 100VDC.
PV Overcurrent
The controller will limit the battery charging current to the
maximum battery current rating. Therefore, an over-sized solar
array will not operate at peak power.
Load Overload
If the current exceeds the maximum load current rating 1.05
times, the controller will disconnect the load. Overloading must
be cleared up by reducing the load and restarting the controller.
Load Short Circuit
Fully protected against the load wiring short-circuit. Once the
load short (more than quadruple rate current), the load short
protection will start automatically. After 5 automatic load
reconnect attempts, the faults must be cleared by restarting the
controller.
PV Reverse Polarity
The controller will not operate if the PV wires are switched. Wire
them correctly to resume normal controller operation.
Battery Reverse
Polarity
The controller will not operate if the battery wires are switched.
Wire them correctly to resume normal controller operation.
Over-Temperature
If the temperature of the controller heat sink exceeds 65OC, the
controller will automatically start the reducing the charging
current and shut down when temperature exceeds 80OC