Renogy ROVER 60 AMP 12V/24V/36V/48V MPPT Common Positive Solar Charge Controller Regulator Compatible

General Information

The Rover PG Series charge controllers are Intelligent positive ground controllers 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 PG’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/24V/36V/48V DC system voltages
• Innovative MPPT technology with high tracking efficiency up to 99% and peak conversion efficiency of 98%
• Deep cycle Sealed, Gel, Flooded and Lithium 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
• RS232 port to communicate with BT-1 Bluetooth Module or DM-1 4G Data ModuleCharges over discharged lithium batteries
• Positive ground charge controller

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 solar panels is the same power that is transmitted into the battery bank. Power is the product of Voltage (V) x Amperage (A).

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.

Four Charging Stages

The Rover PG 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 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.

Lithium Battery Activation

The Rover PG 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 PG 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.

Common Positive Grounding

The Rover PG series are positive ground controllers. This means all positive terminals are bonded together. Any positive connection of solar, load or battery can be earth grounded as required. The solar panels, loads and battery will be connected to the Rover PG the same way as a negative ground controller. The difference is when grounding the Rover PG there can only be a single ground point, either ground the positive line of the solar panels, the positive line of the load terminal or the positive line of the battery bank. Do not ground the Rover PG when adding it to a negative ground system.

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.

Mounting Brackets;

These brackets can be used to mount the Rover PG MPPT charge controller on any flat surface. The screws to mount the brackets to the charge controller are included, screws to mount charge controller to surface are not included.

Optional Components

Optional components that require a separate purchase:

Renogy BT-1 Bluetooth Module:

The BT-1 Bluetooth module is a great addition to any Renogy charge controllers with a RS232 port and is used to pair charge controllers with the Renogy BT 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.

Renogy DM-1 4G Data Module:

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 system parameters remotely from anywhere 4G LTE network service is available

Identification of Parts

Key Parts

1. Charging Indicator
2. Battery Indicator
3. Load Indicator
4. Abnormality Indicator
5. LCD Screen.
6. Operating Keys
7. Installation Hole
8. Solar panel “+" Interface
9. Solar panel Interface
10. Battery Interface
11. Load Interface
12. Battery “+” Interface
13. Load “+” Interface
14. External Temperature Sampling Interface
15. Battery Voltage Compensation Interface
16. RS485 Communication Interface
17. RS232 Communication Interface

Installation

Recommended tools to have before 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.

Warning: Do NOT connect any inverters or battery changers into the LOAD TERMINAL of the charge controller.

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.

Remove Cover

Battery

Solar Panels

Load (optional)

Bluetooth Module communication (optional)

Temperature Sensor (optional, not polarity sensitive)

Install Cover

Mounting Recommendations

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.

Using Mounting Holes

Step 1. Measure the distance between each mounting hole on the Rover PG. Using that distance drill 4 screws onto desired surface.

Step 2. Align the Rovers mounting holes with the screws

Step 3. Verify all screw heads are Inside the mounting holes. Release controller and check if mounting feels secure

Using Mounting Brackets

Step 1. Install the brackets using the provided components

Step 2. Align the mounting brackets to desired surface and use the appropriate screws to drill surface(screws not included)

Step 3. Verify mounting is secure

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.

Main Display

	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

Main Menu

Icon or Value	State	Description
	Steady on	Nighttime
	Steady on	Daytime
	Steady on	A dynamic arrow indicates charging is in progress.
	0-100%	Current battery capacity
	0% Slow Flashing	Battery over-discharged
	100% Flash Flashing	Battery over-voltage
	Steady on	Load Terminal in on
	Steady on	Load Terminal is off
	Fast Flashing	Overload or short-circuit protection

Real-Time Monitoring

To view this screen in the main menu, tap the Right arrow button. To change between screens, press the up or down buttons. To return to the main menu screen press the left arrow button.

Programming Load Terminal

1. If the characters displayed on top of "<Mode>" are "ON", it indicates that the load is switched on
2. Tap " Right Arrow Button" to enter the load setting mode, and right below the "<Mode>", the mode characters or digits will begin to flash. Use" Up and Down Arrow Buttons" to select any one from the load modes listed in the following table and tap " Right Arrow Button" again to complete the load mode setting.
3. Press and hold" Right Arrow Button" in any menu but not the setting mode: if the current load mode is "manual mode", pressing and holding the key will switch on/ off the load; if the current load mode is not "manual mode , pressing and holding the key will cause the display to skip to the load mode setting interface and a reminder wifi pop up telling the user in this mode, pressing and holding the key will not switch on/ off the load.

Load Mode Options

Parameter Settings

To enter the following settings, in the parameters setting screen press the Right arrow button.

Statistical Data

To enter the following settings, in the Statistical Data screen press the Right arrow button.

Historical Data

To enter the following settings, in the Historical Data screen press the Right arrow button.

Device Information

To enter the following settings, in the Device Information screen press the Right arrow button.

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.

Rover PG Protections

System Status Troubleshooting

Maintenance

Warning: Risk of Electric Shock! Make sure that all power is turned off before touching the terminals on the charge controller.

For best controller performance, it is recommended that these tasks be performed from time to time.

1. Check that controller is mounted in a clean, dry, and ventilated area.
2. Check wiring going into the charge controller and make sure there is no wire damage or wear.
3. Tighten all terminals and inspect any loose, broken, or burnt-up connections.
4. Make sure LED readings are consistent. Take necessary corrective action.
5. Check to make sure none of the terminals have any corrosion, insulation damage, high temperature, or any burnt/discoloration marks.

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