Renogy ROVER Series User manual

Rover 100A Version 1.4
Maximum Power Point Tracking Solar Charge Controller
ROVER
SERIES

01
General Safety Information
Charge Controller Safety
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.
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.
NEVER connect the solar panel array to the controller without a battery. Battery must be
connected first.
Ensure input voltage does not exceed 150 VDC to prevent permanent damage. Use the
Open Circuit Voltage (Voc) to make sure the voltage does not exceed this value when
connecting panels together.
Read all of the instructions and cautions in the manual before beginning the installation.
Do NOT allow water to enter the controller.
NOTE
CAUTION
WARNING
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

02
Battery Safety
Use only sealed lead-acid, flooded, gel or lithium 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.
Equalization is carried out only for non-sealed / vented/ flooded / wet cell lead acid
batteries.
Do NOT equalize VRLA type AGM / Gel / Lithium cell batteries UNLESS permitted by
battery manufacturer.
Carefully read battery manuals before operation.
Do
NOT let the positive (+) and negative (-) terminals of the battery touch each other.
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
Recycle battery when it is replaced.
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.

Table of Contents
03
General Information
Additional Components
Optional Components
Identification of Parts
04
08
08
09
Installation 10
Operation
Protections
System Status Troubleshooting
15
LED Indicators 24
25
26
Error Codes 27
Maintenance 27
FusingFusing
Technical Specifications
Electrical Parameters
Battery Charging Parameters
PV Power – Conversion Efficiency Curves
Dimensions
28
29
29
29
31
32
34
General

04
General Information
Customizable charging voltages
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.
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.
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 solar panels is the
same power that is transmitted into the battery bank. Power is the product of Voltage (V) x
Amperage (A).
Automatically detect 12V/24V/36V/48V DC system voltages
Deep cycle Sealed, Gel, Flooded and Lithiumbattery option ready
Electronic protection: Overcharging, over-discharging, overload, and short circuit
Innovative MPPT technology with high tracking efficiency up to 99% and peak
conversion efficiency of 98%
Reverse protection: Any combination of solar module and battery, without causing
damage to any component
RS232 port to communicate with BT-1 Bluetooth module or DM-1 4G Date Module
MPPT Technology
Current Boost
Key Features
Charges over discharged lithium batteries

05
Therefore, assuming 100% efficiency:
Power In = Power Out
Volts In * Amps In = Volts out * Amps out
Maximum
Power Point
Traditional
Controller
Operating
Range
Maximum
Power Point
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.
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.
Limiting Effectiveness
Current vs. Voltage (12V System)Output Power(12V System)
Typical Battery
Voltage Range

06
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).
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 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.
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.
Four Charging Stages
Time
Time
Battery
Current
Battery
Voltage
Equalize
Boost
Float
Recharge
AB C
Boost
Bulk Charging
Max Current
Cumulative Time:3h
Duration Time:2h
(Range:10~180min)
Bulk
Constant Charging Float Charging

07
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 30 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.
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.
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.
WARNING
WARNING
WARNING
The Rover MPPT charge controller has a reactivation feature to awaken a sleeping lithium
battery. The protection circuit of lithium battery will typically turn the battery off and make it
unusable if over-discharged. This can happen when storing a lithium battery 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 reactivate and recharge batteries, these batteries would
become unserviceable and the packs would be discarded. The Rover 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.
Lithium Battery Activation

08
Additional Components
Additional components included in the package:
Optional components that require a separate purchase:
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.
The Bluetooth module is a great addition to any Renogy charge controllers
with a RS232 or RS485 port and is used to pair charge controllers with the
Renogy DC Home App. After pairing is done you can monitor your system
and change parameters directly from you cell phone or tablet. No more
wondering how your system is performing, now you can see performance
in real time without the need of checking on the controller’s LCD.
This communication cable is needed to parallel two or more Rover 100A
charge controllers. Paralleling 100A Rovers allows for higher wattage
systems.
NOTE
This cable should only be used to parallel two Rover
100A charge controllers.
Renogy BT-1 & BT-2 Bluetooth Module:
Remote Temperature Sensor:
Controller Paralleling Cable:
Figure 1
Optional Components
The DM-1 4G Module is capable of connecting to select Renogy charge
controllers through an RS232, and is used to pair charge controllers with
Renogy 4G monitoring app. This app allows you to conveniently monitor
your system and charge syeters parameters remotely from anywhere 4G
LTE network service is available.
Renogy DM-1 4G Data Module:

Key Parts
09
Identification of Parts
1.PV LED Indicator
2.Battery LED Indicator
3.Controller Parallel LED Indicator
4.System Error LED Indicator
5.LCD Screen
6.Operating Keys
7.Mounting Holes
8.PV Terminals
9.Battery Terminals
10.RS485 Port (Optional Accessory)
11.Remote Temperature Sensor/ Battery Remote Port/ Controller Parallel
Port (Optional Accessory)
12.RS232 Port (Optional Accessory)
○
9
○
10 ○
11 ○
12
○
8
○
6
○
5
○
3
○
4
○
2
○
1
○
7

10
Installation
Connect battery terminal wires to the charge controller FIRSTthen connect the solar
panel(s) to the charge controller. NEVER connect solar panel to charge controller before
the battery.
Recommended tools to have before installation:
Screwdriver
INVERTER
BATTERY
CHARGER
HIGH AMP
DRAWING DEVICE
Do not 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.
Multi-Meter
CAUTION
CAUTION
WARNING

1. Remove Cover
2. Connect Battery
3. Connect Solar Panels
11

4. Bluetooth Module communication (optional)
6. Install Cover
Secure the Temperature Sensor lug to one of the battery posts
12
5. Temperature Sensor ( not polarity sensitive)

13
7. Paralleling Function (Optional)
NOTE
Use the provided paralleling cable to combine multiple Rover 100A Charge
Controllers. Connect the cable into the port labeled Parallel Operation on each
Rover 100A. Using this function will allow the Rover to act as one large charge
controller (Example above 300A).
Parallel Port

14
Mounting Recommendations
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).
3. Mark Holes
4. Drill Holes
5. Secure the charge controller.
WARNING
6 inches
warm air
(150mm)
cool air
6 inches
(150mm)

15
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.
Displays solar panels Voltage and Wattage production
on left side of screen. Shows Voltage and Amperage
being sent to the battery on the right side of the screen
To cycle through the Main Menu screens, press the UP or DOWN buttons.
Main Display
Screen 1
Screen 2
Displays solar panels Voltage and Current production
PV BATT
0A
0W
0V 13.0V
PV VOLT
0V
PV CURR
0A
BATT VOLT
13.0V
CHARGE CURR
0A
CHARGE STATUS
DISCHARGE
E0
NORMAL
BATT MAX VOLT ON THE DAY
BATT MIN VOLT ON THE DAY
13.4V
12.6V
BATT CHARGE KWH TODAY
BATT CHARGEKWH/DAY
0KWH
1.927KWH
DEVICE TEMPERATURE
BATT TEMPERATURE
29℃
25℃
PV VOLT
0V
PV CURR
0A
PV BATT
0A
0W
0V 13.0V

16
Screen 6
Screen 5
Screen 4
Screen 3
Displays battery Voltage and charging Current
Shows charge controllers current charging stage
(Discharge, Boost, Float and Equalize).
Displays Error code and controller’s status
Displays Maximum and Minimum battery voltage
throughout the day
BATT VOLT
13.0V
CHARGE CURR
0A
CHARGE STATUS
DISCHARGE
BATT MAX VOLT ON THE DAY
BATT MIN VOLT ON THE DAY
13.4V
12.6V
E0
NORMAL

17
Displays ambient temperature and battery temperature
(Remote temperature sensor needed)
Displays Kilowatt hours charged today, and average
Kilowatt hours charged per day
Use the UP and DOWN buttons then press OK button
to enter the desired setting.
1. Device Set
System Settings Display
Screen 8
Screen 7
To enter the following screen long press OK button on any of the main menu screens.
1. Device ID: Controller’s model number
2. BackLight Time: On/Off
3. Error Alarm: On/Off
4. SOC: Turns SOC % on main display on/off
BATT CHARGE KWH TODAY
BATT CHARGEKWH/DAY
0KWH
1.927KWH
DEVICE TEMPERATURE
BATT TEMPERATURE
29℃
25℃
Set Menus
1.Device Set
2.Parameter Set
3.System Log
4.Password
5.Factory Reset
6.Device Information
1.Device ID: C100-0001
2.BackLight Time: ON
3.Error Alarm: OFF
4.SOC: ON

18
2. Parameter Set
5. Chg Limit Volt: User can set the charge controller’s
maximum charging Voltage
6. Equa Volt: User can set the Equalization Voltage
7. Boost Volt: User can set the Boost Voltage
8. Float Volt: User can set the Float Voltage
9. Boost Return Volt: User can set the Boost Return
Voltage (Voltage when charge controller will re-enter
boost stage.
10. Batt LVR: User can set Low Voltage Reconnect
11. Batt UVW: User can set Under Voltage Warning
12. Batt LVW: User can set Low Voltage Warning
13. EquaChg Time: User can set Equalization time
14. Boost Chg Time: User can set Boost time
15. Equa INV: User can set Equalization interval
16. Temp Comp: User can set Temperature compensation
1. Sys Batt Volt: User can change between
(Auto/12V/24V/36V/48V)
2. Batt Type: User can change between Sealed (SLD),
Gel, Flooded (FLD), Lithium (Li) and User (USE)
3. Battery Capacity: User can set battery bank’s Amp
hour capacity
4. Batt OVD: User can set battery over voltage disconnect
1.Sys Batt Volt: AUTO(12V)
2.Batt Type: SLD
3.Batt Capacity: 200
4.Batt OVD: 16.0V
5.Chg Limit Volt: 15.5V
6.Equa Volt: 14.6V
7.Boost Volt: 14.4V
8.Float Volt: 13.8V
13.Equa Chg Time: 120MIN
14.Boost Chg time: 120MIN
15.Equa INV: 30D
16.Temp Comp: -3mV/℃/2V
9.Boost Return Volt: 13.2V
10.Batt LVR: 12.6V
11.Batt UVW: 12.0V
12.Batt LVW: 11.1V

19
Press UP or DOWN buttons to select the desired day
1. Same day: View system information for current day
2. History: View Historical data
3. Total: View system overall generation
MinBatVol: Batteries lowest voltage for current day
MaxBatVol: Batteries highest voltage for current day
MaxChgCurr: Maximum charging current (Amps) for
current day
MaxChgPow: Maximum charging power (Watts) for
current day
Charge AH: Battery Amp hours charged for current day
Charged KWH: Battery Watt hours charged for current day
MinBatVol: Batteries lowest voltage for current day
MaxBatVol: Batteries highest voltage for current day
MaxChgCurr: Maximum charging current (Amps) for
current day
MaxChgPow: Maximum charging power (Watts) for
current day
Charge AH: Battery Amp hours charged for current day
Charged KWH: Battery Watt hours charged for current day
3. System Log
1.Same day
2.History
3.Total
Choose History Day
0001 Days Ago
Same day
MinBatVol: 13.4V
MaxBatVol: 13.4V
MaxChgCurr: 0A
MaxChgPow: 0W
Charged AH: 0AH
Charged KWH: 0KWH
0001 Days Ago
MinBatVol: 11.5V
MaxBatVol: 12.6V
MaxChgCurr: 0A
MaxChgPow: 0W
Charged AH: 0AH
Charged KWH: 0KWH