Voyager 20A PWM Waterproof PWM Controller Instructions
- June 6, 2024
- Voyager
Table of Contents
The Traveler Series™: Voyager
20A PWM
Waterproof PWM Controller w/ LCD Display and LED Bar
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:
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 the installation.
Charge Controller Safety
- NEVER connect the solar panel array to the controller without a battery. The 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.
Battery Safety
- Lead-acid, Lithium-ion, LiFePO4, LTO batteries can be dangerous. Ensure no sparks or flames are present when working near batteries. Refer to the battery manufacturer’s specific charging rate setting. Do NOT charge improper battery type.Never attempt to charge a damaged battery, frozen battery, or non-rechargeable battery.
- 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 a 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.
- If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eye, immediately flush the eye running with cold water for at least 10 minutes and get medical attention immediately.
WARNING Connect battery terminals to the charge controller BEFORE connecting the solar panel(s) to the charge controller. NEVER connect solar panels to the charge controller until the battery is connected.
General Information
The Voyager is an advanced 5-stage PWM charge controller suitable for 12V solar system applications. It features an intuitive LCD displaying information such as charging current and battery voltage, as well as an error code system to quickly diagnose potential faults. The Voyager is completely waterproof and suitable for charging up to 7 different battery types, including lithium-ion.
Key Features
- Smart PWM technology, high efficiency.
- Backlit LCD displaying system operating information and error codes.
- LED Bar for easy to read charge state and battery information.
- 7 Battery Type Compatible: Lithium-ion, LiFePO4, LTO, Gel, AGM, Flooded, and Calcium.
- Waterproof design, suitable for indoor or outdoor use.
- 5 Stage PWM charging: Soft-Start, Bulk, Absorption. Float, and Equalization.
- Protection against: reverse polarity and battery connection, reverse current from battery to solar panel protection at night, over-temperature, and over-voltage.
PWM Technology
The Voyager 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.
Five Charging Stages
The Voyager has a 5-stage battery charging algorithm for rapid, efficient, and
safe battery charging. They include Soft Charge, Bulk Charge, Absorption
Charge, Float Charge, and Equalization.
Soft Charge:
When batteries suffer an over-discharge, the controller will softly ramp the
battery voltage up to 10V.
Bulk Charge:
Maximum battery charging until batteries rise to Absorption Level.
Absorption Charge:
Constant voltage charging and battery is over 85% for lead-acid batteries.
Lithium-ion, LiFePO4, and LTO batteries will close fully charging after the
absorption stage, the absorption level will reach 12.6V for Lithium-ion, 14.4V
for LiFePO4, and 14.0V for LTO batteries.
Equalization:
Only for Flooded or Calcium batteries drained below 11.5V will automatically
run this stage and bring the internal cells to an equal state and fully
complement the loss of capacity.
Lithium-ion, LiFePO4, LTO, Gel, and AGM do not undergo this stage.
Float Charge:
The battery is fully charged and maintained at a safe level. A fully charged
lead-acid battery (Gel, AGM, Flooded) has a voltage of more than 13.6V; if the
lead-acid battery drops to 12.8V at float charge, it will return to Bulk
Charge. Lithium-ion, LiFePO4, and LTO have NO float charge. If a Lithium-to
Bulk Charge. If a LiFePO4 or LTO battery voltage drops to 13.4V after
Absorption Charge, it will return to Bulk Charge.
WARNING Incorrect battery type settings may damage your battery.
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.
Charging Stages
Soft-Charge| Output battery voltage is 3V-10VDC, Current = half of the solar
panel current
---|---
Bulk| 10VDC to 14VDC
Current = Rated Charge Current
Absorption
@ 25°C
| Constant voltage until current drops to 0.75/1.0 amps and holds for 30s.
Minimum 2 hours charging time and maximum 4 hours time out If charging current
< 0.2A, stage will end.
Li-ion 12.6V| LiFePO4 14.4V| LTO 4.0V| GEL 14.1V| AGM 14.4V| WET 14.7V|
CALCIUM 14.9V
Equalization| Only Wet (Flooded) or Calcium Batteries will equalize, 2 hours
maximum
Wet (Flooded) = if discharge below 11.5V OR every 28 days charging period.
Calcium = every charging cycle
Wet (Flooded) 15.5V| Calcium 15.5V
Float| Li-ionN/A| LiFePO4
N/A| LTO
N/A| GEL
13.6V| AGM
13.6V| WET
13.6V| CALCIUM
13.6V
Under Voltage Recharging| Li-ion12.0V| LiFePO4
13.4V| LTO13.4V| GEL
12.8V| AGE
12.8V| WET
12.8V| CALCIUM
12.8V
Identification of Parts
Key Parts
- Backlit LCD
- AMP/VOLT Button
- BATTERY TYPE Button
- LED Bar
- Remote Temperature Sensor Port (optional accessory)
- Battery Terminals
- Solar Terminals
Installation
WARNING
Connect battery terminal wires to the charge controller FIRST then connect the
solar panel(s) to the charge controller. NEVER connect the solar panel to the
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. 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.
The Voyager is designed for vertical mounting on a wall.
- 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
- Secure the charge controller
Wiring
The Voyager has 4 terminals which are clearly labeled as “solar” or “battery”.
NOTE The solar
controller should be installed as near the battery as possible to avoid
efficiency loss.
NOTE When the connections are completed correctly, the solar controller
will turn on and begin working automatically.
Distance Wiring
Cable Total Length One-Way Distance| < 10ft| 10ft-20ft
Cable Size (AWG)| 14-12AWG| 12-10AWG
NOTE The solar controller should be installed as near the battery as
possible to avoid efficiency loss.
NOTE When the connections are completed correctly, the solar controller
will turn on and begin working automatically.
Operation
When the controller powers on, the Voyager will run a self-quality check mode and automatically display the figures on LCD before going into auto work.
| Self-test starts, digital meter segments test
---|---
| Software version test
| Rated voltage Test
| Rated Current Test
| External battery temperature sensor test (if connected)
Selecting Battery Type
WARNING Incorrect battery type settings may damage your battery. Please
check your battery manufacturer’s specifications when selecting battery type.
The Voyager provides 7 battery types for selection: Lithium-ion, LiFePO4, LTO,
Gel, AGM, Flooded, and Calcium Battery.
Press and hold the BATTERY TYPE Button for 3 seconds to go into battery
selection mode. Press the BATTERY TYPE Button until the desired battery is
displayed. After a few seconds, the highlighted battery type will
automatically be selected.
NOTE Lithium-ion batteries shown in the LCD indicate different types
shown below:
Lithium Cobalt Oxide LiCoO2 (LCO) battery
Lithium Manganese Oxide LiMn2O4 (LMQ) battery
Lithium Nickel Manganese Cobalt Oxide LiNiMnCoO2 (NMC) battery
Lithium Nickel Cobalt Aluminum Oxide LiNiCoAlo2 (NCA) battery
LiFePO4 battery indicates Lithium-iron Phosphate or LFP Battery
LTO Battery indicates Lithium Titanate Oxidized, Li4Ti5O12 Battery
AMP/VOLT Button
Pressing the AMP/VOLT Button will sequence through the following display
parameters:
Battery Voltage, Charging Current, Charged Capacity (Amp-hour), and Battery
Temperature (if external temperature sensor connected)
Normal Sequencing Display
The following is an alternative display voltage for when the battery is fully charged
LED Behavior
LED Indicators
| | | 
---|---|---|---
LED Color| RED| BLUE| RED| ORANGE| GREEN| GREEN
Soft-start charging| ON| LASH| ON| OFF| OFF| OFF
Bulk charging
cpv < 11.5V1| ON| ON| ON| OFF| OFF| OFF
Bulk charging (11.5V<BV<12.5V)| ON| ON| OFF| ON| OFF| OFF
Bulk charging ( BV > 12.5V )| ON| ON| OFF| OFF| ON| OFF
Absorption charging| ON| ON| OFF| OFF| ON| OFF
Float charging| ON| OFF| OFF| OFF| OFF| ON
Solar weak
( Dawn or Dusk )| FLASH| OFF| | According to BV| OFF
In the night| OFF| OFF| | I
OFF
NOTE BV = Battery Voltage
LED Error Behavior
LED Indicators
| | | | Error
Code
| Screen
---|---|---|---|---|---
LED Color| RED| BLUE| RED| ORANGE| GREEN| GREEN| |
‘Solar good, BV
<3V| ‘ ON| OFF| FLASH| OFF| OFF| OFF| ‘b01’| FLASH
Solar good battery reversed| ON| OFF| FLASH| OFF| OFF| OFF| ‘b02’| FLASH
Solar good, battery over-voltage| ON| OFF| FLASH| FLASH| 6
FLASH| OFF| ‘b03’| FLASH
Solar off, battery over-voltage| OFF| OFF| FLASH| FLASH| FLASH| OFF| ‘b03’|
FLASH
Solar good, battery over 65°C| ON| OFF| FLASH| FLASH| FLASH| OFF| ‘b04’| FLASH
Battery good, solar reversed| FLASH| OFF| According to BV| OFF| ‘PO1’| FLASH
Battery good, solar over-voltage| FLASH| OFF| OFF| ‘PO2’| FLASH
r Over Temperature| | ‘otP’| _FLASH
Protection
System Status Troubleshooting
| Description | Troubleshoot |
|---|---|
| Battery 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.
The charge controller does not charge during the 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.
Look for error codes
Maintenance
For best controller performance, it is recommended that these tasks be performed from time to time.
- 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
- Occasionally clean the case using a damp cloth
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
Technical Specifications
Electrical Parameters
| Model Rating | 20A |
|---|---|
| Normal Battery Voltage | 12V |
| Maximum Solar Voltage(OCV) | 26V |
| Maximum Battery Voltage | 17V |
| Rated Charging Current | 20A |
| Battery Start Charging Voltage | 3V |
| Electrical Protection and Feature | Spark-free protection. |
Reverse polarity solar and battery connection
Reverse current from the battery to solar panel
protection at night
Over-temperature protection with derating
charging current
Transient overvoltage protection, at the solar input and battery output,
protects against surge voltage
Grounding| Common Negative
EMC Conformity| FCC Part-15 class B compliant; EN55022:2010
Self-consumption| < 8mA
Mechanical Parameters
Dimensions| L6.38 x W3.82 x H1.34 inches
Weight| 0.88 lbs.
Mounting| Vertical Wall Mounting
Ingress Protection Rating| IP65
Maximum Terminals Wire Size| 10AWG(5mm2
Terminals Screw Torque| 13 lbf·in
Operating Temperature| -40°F to +140°F
Meter Operating Temperature| -4°F to +140°F
Storage Temperature Range| -40°F to +185°F
Temp. Comp. Coefficient| -24mV / °C
Temp. Comp. Range| -4°F ~ 122°F
Operating Humidity| 100% (No condensation)
Dimensions
2775 E. Philadelphia St., Ontario, CA 91761
1-800-330-8678
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notice.
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