Renogy Rover RNG-CTRL-RVR60-G1 User Manual
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Renogy Rover RNG-CTRL-RVR60-G1 User Manual

60 amp mppt solar charge controller
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Rover
60 Amp MPPT Solar Charge Controller
12V/24V/36V/48V 60A
VERSION A4
RNG-CTRL-RVR60-G1
June 24, 2024
USER MANUAL

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Summary of Contents for Renogy Rover RNG-CTRL-RVR60-G1

  • Page 1 Rover 60 Amp MPPT Solar Charge Controller 12V/24V/36V/48V 60A VERSION A4 RNG-CTRL-RVR60-G1 June 24, 2024 USER MANUAL...
  • Page 2 The illustrations in the user manual are for demonstration purposes only. Details may appear slightly different depending on product revision and market region. z Renogy reserves the right to change the information in the user manual without notice. For the latest user manual, visit renogy.com.

  • Page 3: Table Of Contents

    Table of Contents General Information ........................... 1 1.1. Symbols Used .............................. 1 1.2. Qualified Personnel............................. 1 1.3. Introduction ..............................1 1.4. Key Features ..............................1 1.5. SKU ................................2 Get to Know Rover 60 Amp MPPT Solar Charge Controller ............2 2.1.
  • Page 4 11.2. Technical Specifications ......................... 54 12. Maintenance ............................55 12.1. Inspection ..............................55 12.2. Cleaning ..............................55 12.3. Storage ............................... 56 13. Emergency Responses ........................56 13.1. Fire ................................56 13.2. Flooding ..............................56 13.3. Smell ................................56 13.4. Noise ................................56 Renogy Support ............................57...

  • Page 5: General Information

    1. General Information 1.1. Symbols Used The following symbols are used throughout the user manual to highlight important information. WARNING: Indicates a potentially hazardous condition that could result in personal injury or death. CAUTION: Indicates a critical procedure for safe and proper installation and operation. NOTE: Indicates an important step or tip for optimal performance.

  • Page 6: Sku

    1.5. SKU Rover 60 Amp MPPT Solar Charge Controller RNG-CTRL-RVR60 2. Get to Know Rover 60 Amp MPPT Solar Charge Controller 2.1. What’s In the Box? Rover 60 Amp MPPT Solar Charge Controller Rover 60 Amp MPPT 12V/24V/36V/48V 60A RNG-CTRL-RVR60-G1 VERSION A4 June 24, 2024 Solar Charge Controller ×...

  • Page 7: System Setup

    █ Interior (with the cover removed) Battery Voltage Compensation lnterface Controller Parallel Port RS232 Communication Interface External Temperature Sampling lnterface RS485 Communication Interface Cable Retainers Solar Positive Terminal Solar Negative Terminal Battery Negative Terminal Load Negative Terminal Battery Positive Terminal Load Positive Terminal 2.3.

  • Page 8: Wiring Setup

    In this manual, the red cable represents the positive cable, and the gray cable represents the negative cable. *Only install either the Renogy BT-1 Bluetooth Module or the Renogy BT-2 Bluetooth Module, as either one of them is sufficient. Always connect the battery terminals before the solar panel terminals.

  • Page 9: Preparation

    3. Preparation 3.1. Plan a Mounting Site The charge controller requires adequate clearance for installation, wiring, and ventilation. The minimum clearance is provided below. Ventilation is highly recommended if it is mounted in an enclosure. Select a proper mounting site to ensure the charge controller can be safely connected to the battery, solar panel(s), and the other necessary devices with the relevant cables.

  • Page 10: Recommended Tools

    To ensure good ventilation and optimal system performance, we recommend mounting the charge controller vertically (terminals down) on a wall or horizontally on the floor. 3.2. Recommended Tools Phillips Screwdriver (#2) Insulating Gloves Wire stripper Insulation Tape Wrench (10 mm) Wrench (14 mm) Measuring Tape Prior to installing and configuring the charge controller, prepare the recommended tools,...

  • Page 11: Check The Charge Controller

    Battery (9V to 64V) Cables (6 AWG) × 2 (6 AWG) × 1 Components and accessories marked with “*” are available on renogy.com. 1. Inspect the battery for any visible damage including cracks, dents, deformation, and other visible abnormalities. All terminals shall be clean, free of dirt and corrosion, and dry.
  • Page 12 Do not use the battery if there is any visible damage. Do not touch the exposed electrolyte or powder if the battery housing is damaged. When being charged, the battery may give off explosive gas. Make sure there is good ventilation. Take care to use a high-capacity lead-acid battery.

  • Page 13: Check The Solar Panel(S)

    *Solar Panel Fuse *Solar Panel Extension Cables × 2 Components and accessories marked with “*” are available on renogy.com. Select proper wires based on the operating current of the specific device in your power system. The table below lists recommended gauge sizes in accordance with National Electrical Code (NEC).
  • Page 14 Do not install the solar panel on a surface constructed from combustible material. Do not expose the solar panel to direct flame or heat sources. Keep the solar panel out of the reach of children. Keep the solar panel away from explosives and corrosive substances. Do not step, walk, stand, or jump on the solar panel.
  • Page 15 For details about how to connect solar panels in series, parallel, and series-parallel, refer to Guide Between Series and Parallel Connections on Renogy Learning Center. 5. The appropriate current rating for the solar panel fuse should be determined by multiplying the total amperage of the solar panel array by 1.56.

  • Page 16: How To Install Cables On The Charge Controller

    3.6. How to Install Cables on the Charge Controller? The wiring method applies to all adapter cables. This manual uses the negative battery adapter cable as an example. Step 1: Strip approximately 0.8 inches (20 mm) of insulation from the end of an adapter cable using a wire stripper. 0.8 in (20 mm) Step 2: Rotate the cable retainer of the Battery Negative Terminal...

  • Page 17: Installation

    4. Installation To ensure safe and efficient operation of the charge controller and to avoid potential damage or hazards, always follow the installation instructions in the sequence described in this manual. Connect the battery to the charge controller before the solar panel. Reverse polarity protection does not apply if the solar panel is connected to the charge controller before the battery.
  • Page 18 █ Method 2: Mounting via Integrated Holes (Wall-mounted) Recommended Tools ≤ 0.17 in ≤ 4.5 mm ≥ 11.61 in ≥ 295 mm ≥0.4 in ≥ 10 mm ≥ 8.46 in ≥ 215 mm Installation Template (Letter Size) Marker Pen Self-tapping Screws The following steps provide an example of mounting the charge controller on a wall.
  • Page 19 Step 4: Tear off the paper. Step 5: Hang the charge controller onto the wall and verify all screw heads are in the mounting holes. Step 6: Release the charge controller and slide it down into place. Tighten the screws. Step 7: If the screws are not secure, tighten them clockwise with a suitable wrench.

  • Page 20: Remove The Charge Controller Cover

    █ Method 3: Mounting Using Included Brackets Recommended Tools ST4.5 mm Self-tapping Screws x 4 Mounting the charge controller is relatively easy. Follow the steps below: Step 1: Secure the Mounting Brackets on the mounting holes of the charge controller with proper screws. The diagram shows the installation of the right side's two Mounting Brackets.

  • Page 21: Connect The Charger Controller To An Auxiliary Battery

    4.4. Connect the Charger Controller to an Auxiliary Battery Step 1: Rotate the cable retainers of the BAT-, and BAT+ terminals counterclockwise with a screwdriver. Make sure the cable retainers are completely open. Step 2: Strip approximately 0.8 inches (20 mm) of insulation from the end of an adapter cable using a wire stripper.

  • Page 22: Connect The Charger Controller To A Solar Panel

    Once the cables are connected to the battery, the LCD and the Battery LED Indicator will light up, and the charge controller enters nighttime mode. Identify the polarities (positive and negative) on the cables used for the batteries. A reverse polarity contact may damage the charge controller.

  • Page 23: Install A Dc Load (Optional)

    4.6. Install a DC load (Optional) You can choose to connect the charge controller to a DC load (≤20A) on demand. Recommended Accessories Bare Wires (14 AWG) × 2 DC load operating current needs to be less than or equal to 20A. Select appropriate cables based on the DC load operating current.

  • Page 24: Install A Battery Temperature Sensor

    Recommended Accessories *Battery Voltage Sensor Accessories marked with “*” are available on renogy.com. Step 1: Connect the terminal block to the Battery Voltage Compensation lnterface on the charge controller. Step 2: Connect the Negative Ring Terminal of the Battery Voltage Sensor to the Negative Terminal on the battery.

  • Page 25: Install A Bluetooth Module (Optional)

    4.9. Install a Bluetooth Module (Optional) With a Renogy BT-1 Bluetooth Module or a Renogy BT-2 Bluetooth Module, the charge controller can be connected to the DC Home app for remote device monitoring. You can monitor and modify parameters of the charge controller through the DC Home app.
  • Page 26 Make sure that the charge controller is properly installed and powered on before it is paired with the DC Home app. To ensure optimal system performance, keep the phone within 10 feet (3 m) of the Renogy BT-1 Bluetooth Module or a Renogy BT-2 Bluetooth Module.

  • Page 27: Wire Inspection

    Make sure the charge controller does not communicate with any other device. Step 1: Connect the charge controller to Renogy ONE through the Bluetooth of your phone. Step 2: Pair the Renogy ONE with the DC Home app by scanning the QR code on Renogy ONE. Internet...

  • Page 28: Install The Charge Controller Cover

    4.11. Install the Charge Controller Cover Align the two mounting slots on the charge controller, and install the Cover vertically downwards. Use a Phillips Screwdriver (#2) to securely fasten the two Cover Screws on the cover. 5. Operation 5.1. Power On/Off The charge controller powers up upon connection to a battery and/or to a solar panel.

  • Page 29: Lcd Screen

    LED Pattern Description Graphic Expression The LED remains continuously Solid illuminated without any variation. In this mode, the LED alternates between being on and off at Slow Flash a relatively slow and regular interval of 1s. In this mode, the LED alternates between being on and off at a 0.1s 0.1s...

  • Page 30: Setting Buttons

    Icon Parameter Description Solar Panel Indicates the solar panel. z Dynamic: The charge controller is charging the Charging battery. (The arrow between the solar panel and the z Static: The charge controller is not charging the battery) battery. Indicates state of charge of the battery. Value range: 0% to 100% Battery z Slow flashing: 0%, overdischarged...

  • Page 31: Interface Switching

    5.5. Interface Switching The charge controller allows you to configure different parameters in the following distinct interfaces: z Main Interface z Load Mode Setting z Parameter Setting (Charging, discharging, temperature compensation, charging duration, parallel mode and more) z Power Analysis z History z Device Info In the Main Interface, press...

  • Page 32: Set A Battery Type

    5.7. Set a Battery Type Upon installing the charge controller, set a correct battery type in the Parameter Setting Interface. It is essential to ensure that the battery type is set correctly to avoid any potential damage to the charge controller because any damage to the charge controller resulting from an incorrect battery type setting voids the warranty.

  • Page 33: Use Mode

    To set a battery voltage, follow the steps below: Step 1: In the Main Interface, navigate to the Parameter Setting interface by pressing the button on the charge controller. Press to enter the details setting interface. Step 2: Press to jump to the BatSysVol option.
  • Page 34 You can configure the USE Mode on the LCD screen on the charge controller or in the DC Home app. For details on how to configure the mode in the app, see “Monitoring via DC Home or Renogy ONE”. Step 1: In the Main Interface, navigate...
  • Page 35 Step 3: Choose “USE“ by pressing the button . Press to save the settings. Step 4: Press to jump to the parameter (such as BatSysVol and OverVolDsc) that you want to modify. Press to enter the setting interface (indicating by the flashing icon).

  • Page 36: In-Built Lcd Monitoring

    “Monitoring via DC Home or Renogy ONE”.) The LCD screen allows system-wide monitoring while the DC Home app and Renogy ONE Core allow for limited monitoring. You can chose any or all of them based on your needs. The LCD screen illustrations in this chapter are based on 12V systems. For 24V, 36V, and 48V systems, the charge controller automatically doubles, triples, and quadruples the parameter values respectively while remaining the display value as 12V systems.
  • Page 37 You can check the following parameters: Parameter Name Description Indicates the charging status and stage of the charge controller. Options include: z Idle : not charging z MPPT: MPPT charging ChagState z EQU: Equalizing charging z BST: Boost charging z FLT: Float charging z LIMIT: Current-limited charging BatVol Indicates the actual battery voltage.

  • Page 38: Check Power Analysis

    6.2. Check Power Analysis The Rover 60A charge controller allows you to get a glimpse of how much power you have generated and consumed during the operating period. In the Main Interface, navigate to the Power Analysis interface by pressing the button on the charge controller.
  • Page 39 Step 3: Press to save the settings. Press to cancel the setting and exit the setting interface . █ History Details The Rover 60A charge controller allows you to check the battery and load details during the selected collection time. In the History interface, press to check the details.

  • Page 40: Check Device Info

    ONE”. For detailed configuration instructions, please refer to the Renogy ONE Core.) The LCD screen and setting buttons allow full settings while the DC Home app and Renogy ONE Core allow for limited configurations. You can chose any or all of them based on your needs.
  • Page 41 Step 1: In the Main Interface, navigate to the Parameter Setting interface by pressing the button on the charge controller. Press to enter the details setting interface. Step 2: Press to jump to the parameter that you want to modify. Press , and the parameter value flashes.
  • Page 42 Parameter Name Description Indicates the boost charging voltage. BstChgVol Note: This parameter is configurable only when BatType is set to “USE“ or “LI”. Value range: 9.0V to 17.0V Indicates the float charging voltage. FltChgVol Note: This parameter is configurable only when BatType is set to “USE“. Value range: 9.0V to 17.0V Indicates the boost charging return voltage.
  • Page 43 Parameter Name Description z YES: Reset the charge controller to factory mode. <Restore Default> z NO: Exist factory mode restoration. z Communication: Bluetooth z Parallel CHG: In parallel z ON (default): Short-Circuit Protection on LoadShortCrt z OFF: Short-Circuit Protection off (Caution: This may damage the charge controller.) Indicates the maximum charging current.

  • Page 44: Miscellaneous Settings

    Battery Type Supported Range Parameters Boost Return Voltage 13.2V 13.2V 13.2V 13.2V [13.2V] — (BstChgRev) Undervoltage Warning 12.0V 12.0V 12.0V 12.0V [12.0V] — (UndVolWrn) Undervoltage Return — — — — — — (LowVolRev) Low Voltage Disconnect 11.0V 11.0V 11.0V 11.0V 11.1V 9.0-17.0V (LowVolDisc)
  • Page 45 Step 2: Press , to jump to <ClrHistoryData>. Press to enter the settings. ClrHistoryData RestoreDefault 485: communication Step 3: Choose “Yes” by pressing the button . Press to save the settings. ClrHistoryData ClrHistoryData █ Restore to Factory Default You can restore all settings to factory default in the Parameter Setting interface. Factory default restoration is an irreversible action;...
  • Page 46 Step 3: Choose “Yes” by pressing the button . Press to save the settings. RestoreDefault RestoreDefault █ Set LCD Backlight Timer You can configure the duration after which the LCD screen automatically turns off in the event of no activity on the setting buttons. Step 1: In the Main Interface, navigate to the Parameter Setting interface by pressing the...

  • Page 47: Configure Load Output Mode

    7.3. Configure Load Output Mode You can configure the load output status and mode on the charge controller. In the Main Interface, navigate to the Load Mode interface by pressing the button on the charge controller. In the Load Mode interface, you can configure the following: Load Output Status Load Output Mode To modify the Load Output Mode, ensure the Load Output Status is ON.

  • Page 48: Parallel Connection Of Charger Controllers

    The charge controller supports both automated and manual load output modes. The details are listed in the table below: Mode Description Light Control Mode . z The load output will be on when the output voltage of the solar panel is Light+ On below L-CON-V after a specific time period (set by L-CON-T).
  • Page 49 Rover 60A charge controllers communicate with each other via RS-485 communication protocol. A qualified RS-485 communication cable shall meet the following: z RJ45 connectors z Power supply at 5V and 200 mA z Default baudrate: 9600 kps, no parity bit; data bit: 8 bits; stop bit: 1 bit The pinout definitions of a RS-485 communication cable is displayed in the table below: RS-485 Connector Pinout No.

  • Page 50: Set Parallel Mode

    8.2. Set Parallel Mode Before configuring the parallel mode, ensure all charge controllers are installed correctly. Only one charge controller works as the host and the other(s) work(s) as the slave(s). The host charge controller enables centralized management of charging status, phase, and constant charging voltage for all slave controllers.

  • Page 51: Working Logic

    9 Working Logic 9.1. Charging Algorithm Rover 60 Amp MPPT Solar Charge Controller adopts the Maximum Power Point Tracking (MPPT) technology to extract the maximum power from connected solar panels. With an automatic tracking algorithm, the charge controller can track the voltage of the maximum power point that changes with weather conditions, ensuring the harvest of the maximum power throughout the day.

  • Page 52: Adaptive Four-Stage Charging

    9.2. Adaptive Four-Stage Charging Rover charge controller has a four-stage battery charging algorithm for a rapid, efficient, and safe battery charging. The stages include: Bulk Charging, Boost Charging, Float Charging, and Equalization. Reset to Bulk Bulk Float Charge Charge Boost Charge Stage Charge Stage Stage...

  • Page 53: Activate Lithium Batteries

    and for most batteries this could cause damage. Refer to the user manual of the battery or contact the battery manufacturer to see if this stage is needed. During Equalization charging, the charge controller remains in this stage until sufficient charging current is sourced from the solar panel.

  • Page 54: Conversion Efficiency

    9.4. Conversion Efficiency Light Intensity: 1000W/m2 Temperature: 25°C █ MPPT 12V conversion efficiency (12V battery) 20 Vmp 40 Vmp 60 Vmp 90 Vmp 110 Vmp Output power (W) █ MPPT 24V conversion efficiency (24V battery) 100% 40 Vmp 60 Vmp 80 Vmp 90 Vmp 110 Vmp...

  • Page 55: Troubleshooting

    █ MPPT 48V conversion efficiency (48V battery) 60 Vmp 70 Vmp 80 Vmp 90 Vmp 110 Vmp 1000 1250 1500 2000 2500 3000 Output power (W) 10. Troubleshooting When an error occurs, the Error LED Indicator is solid on. You can check the error details on the LCD of the charge controller.
  • Page 56 6. Inspect the cable of the solar panel for any visible damage. 7. Inspect the fuse of the solar panel for any visible damage. For technical support, please contact our customer service through renogy.com/contact-us. The battery needs troubleshooting if it can not be detected. Follow the troubleshooting steps below: 1.
  • Page 57 5. Check the battery voltage. If the battery voltage is too low, charge the battery immediately. For more latest troubleshooting tips, see Troubleshoot Renogy Rover 60A Charger Controller Renogy Learning Center. For technical support, contact our technical service through renogy.com/contact-us. — 53 —...

  • Page 58: Dimensions & Specifications

    11. Dimensions & Specifications 11.1. Dimensions 8.07 in (205 mm) 2.58 in 11.22 in 4.01 in (65.5 mm) (285 mm) (102 mm) 6.69 in (170 mm) Dimension tolerance: ±0.2 in (0.5 mm) 11.2. Technical Specifications Parameter Value Nominal System Voltage 12V/24V/36V/48V Auto Recognition Battery Input Voltage Range 9V to 64V DC...

  • Page 59: Maintenance

    Parameter Value -31°F to 140°F /-35°C to 60°C Operating Temperature (Power reduction above 113°F / 45°C) Storage Temperature -31°F to 167°F / -35°C to 75°C Humidity 0% to 95% RH Cooling Heat Sink Enclosure Rating IP32 Dimensions (LxWxH) 11.20 x 8.10 x 4.00 in / 285 x 205 x 102 mm Weight 7.9 lbs/ 3.6kg Regulatory and Safety...

  • Page 60: Storage

    z Make sure the charge controller is completely dry before reconnecting it to the solar panel and battery. 12.3. Storage Follow the tips below to ensure that the charge controller is stored well. z Disconnect all cables connected to the charge controller. z By applying dielectric grease to each terminals, the dielectric grease repels moisture and protects the connector contacts from corrosion.

  • Page 61: Renogy Support

    Questionnaire Investigation To explore more possibilities of solar systems, visit Renogy Learning Center at: renogy.com/learning-center For technical questions about your product in the U.S., contact the Renogy technical support team through: renogy.com/contact-us 1(909)2877111 For technical support outside the U.S., visit the local website below:...
  • Page 62 FCC Statement This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference. (2) This device must accept any interference received, including interference that may cause undesired operation.
  • Page 63 Save 105 gallons of water from being consumed Renogy Power PLUS Renogy Power Plus allows you to stay in the loop with upcoming solar energy innovations, share your experiences with your solar energy journey, and connect with like-minded people who are changing the world in the Renogy Power Plus community.

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