ROVER BOOST Maximum Power-Point Tracking Boost Charge Controller 36V/48V | 10A Version 1.
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 CAUTION NOTE Indicates a potentially dangerous condition.
Table of Contents General Information Product Description Product Overview 03 03 04 Identification of Parts 04 Dimensions 06 Included Components 07 Optional Components 07 Installation 08 Mounting Recommendations 08 Recommended Gauge and Ring Terminal Sizes 09 Wiring 10 Battery Wiring 10 Solar Panel Wiring 13 Grounding 15 Connecting the Temperature Sensor (RTSCC) 16 Connecting the Battery Voltage Sensor (RVSCC) 16 Operation 17 Auto Recognition and Toggle 17 Set the Battery Typ
General Information Product Description The all-new Rover Boost controller is a 10Amp Maximum Power Point Tracking (MPPT) charge controller engineered to charge a 36V or 48V battery bank from voltage typically found in only 1-2, 36-cell solar modules. Featuring 4-stage battery charging (Bulk, Boost, Float, and Equalization), the Rover Boost is pre-set to be compatible with AGM, Gel, Flooded, and Lithium batteries, and even includes custom battery settings.
Product Overview Identification of Parts 3 rover boost 10a solar charge controller 2 4 1 Top/ Front View 1.Grounding Lug 2.Output Port: 36V or 48V Battery Connections 3.Mounting Holes (4) 4.
10 12 11 6 7 8 9 14 13 SET output TYPE BATT PV rs485 can temp 5 batt Left View 5.RS485 / CAN Communication Ports 10.36/48V Positive Battery Output Terminal 6.Setting Button 11.36/48V Negative Battery Output Terminal （Battery Type，CAN Host Mode） 12.Removable Battery Output Cable Housing 7.Battery Type LED Indicator 13.Battery Voltage Sensor Port 8.Battery Status LED Indicator (Polarity Sensitive, Optional) 9.PV Status LED Indicator 14.
Dimensions [185.0mm] 7.3in [5.0mm] 4xφ0.2in [191.9mm] 7.6in [180.9mm] 7.1in [170.0mm] 6.7in [155.0mm] 6.1in rover boost 10a solar charge controller [115.0mm] 4.5in [74.5mm] 2.9in [223.9mm] 8.8in input [133.3mm] 5.3in NOTE The dimensions have a ±0.5mm tolerance.
Included Components Mounting Screws for the Input/output Terminals The Rover boost terminals are secured not only by tightening the cable entry hatch, but also by utilizing the removable cable housing to secure the incoming and outgoing connections. Optional Components Renogy BT-2 Bluetooth Module (Model: RCM-BT2) The RCM-BT2 is a great addition to any Renogy charge controller with an RS485 port.
Installation WARNING Connect the battery terminal wires to the Charge controller FIRST then connect the solar panels to the charge controller SECOND. Connecting panels before the battery may result in irreversible damage. Never install the controller in a sealed enclosure with flooded batteries as gas may accumulate and there is a risk of explosion. CAUTION Do not over-tighten the terminals. This could potentially break mounting components rendering the controller useless.
Recommended Gauge and Ring Terminal Sizes Ring Width The Rover Boost accepts ring terminals or lugs. Due to the terminal housing, ring terminals must comply with the following instructions Ring Size Cable Width Ring Width Cable Width Ring Size Recommended < 19mm < 3/4” < 14.5mm < 9/16" 6mm 1/4" Specification Recommended AWG Rated Amps Recommended Fusing Battery Wiring 12 AWG 10A 15A-20A The following recommendation is based off 3% maximum voltage loss.
NOTE The Rated Max PV Input Power is 500W (36V) or 650W (48V) Larger wire sizes will improve boost performance whereas smaller wire sizes will reduce boost performance. When considering wiring, fuse, and connection options think big and short as larger heavier components and shorter wire lengths offer less resistance and voltage drop. Wiring WARNING The Rover Boost is only suitable for 36V or 48V battery banks only.
2. Unscrew the negative M6 terminal stud, then place the negative Battery ring terminal onto the negative port and screw the M6 terminal stud and washers together. Repeat the same for the positive M6 terminal stud and positive Battery ring terminal. NOTE The M6 screws have a recommended toque 4.1~5.0 N-m / 3~3.7 lb. ft. 3. When finished, place the removable battery output cable housing back over your connections. Make sure to not over-tighten the M3 screws.
48V 100Ah Wiring Assuming each battery is 12V 100Ah battery bank, you will combine 4 x 12V batteries in series to achieve a 48V 100Ah battery bank. In series connections, the 12V voltages add up to 48V, while the 100Ah Rating remains the same. 10A Rover Boost 12-10AWG Tray Cable 15A-20A ANL Fuse Set+Cable Battery Interconnects 48V Battery System Ground 36V 100Ah Wiring Assuming each battery is 12V 100Ah battery bank, you will combine 3 x 12V batteries in series to achieve a 36V 100Ah battery bank.
Solar Panel Wiring The Rover Boost is designed to automatically utilize MPPT technology to boost wasted power into usable charge current. NOTE WARNING WARNING Ring terminals are recommended for the input and output connections of the Rover Boost. Failure to abide by the chart may result in damage to your system or system components. Please pay close attention to your solar panel specifications when connecting them to the controller. Not compatible with 72 cell PV Modules.
System Voltage Range Rated Max PV Power 36 V 15 ~ 25 VDC 500W 48 V 15 ~ 40 VDC 650W NOTE If the VOC is greater than 45V, charging disconnects; When the VOC is less than 40V, then it resumes charging. CAUTION Exceeding the Rated Max Power will put the controller in Power Limiting Protection Mode up to 600W/36V or 800W/48V. Afterwards the unit will shut down. 1. Locate the INPUT side.
3. When finished, place the removable PV input cable housing back over your connections. Make sure to not over-tighten the M3 screws. NOTE The M3 screws have a recommended torque of 0.5~0.8 N-m / 0.4~0.6 lbf. ft. Typical Setup 200W System, 48V System A typical setup is demonstrated utilizing 2 x 100W panels in parallel where all the positive connectors connect, and all the negative connections connect before they are connected at the input of the Rover Boost.
Connecting the Temperature Sensor (Model: RTSCC) The RTSCC will include the 2-pin green housing connector. Simply connect the 2-pin connector to the TEMP port on the OUTPUT side of the Rover Boost. NOTE Separate purchase required.
Operation The Rover Boost is relatively simple to operate. You will need to set your battery type using the SET button and then the controller can take care of the rest. The LED Indicators and SET button are found on the OUTPUT side of the Rover Boost. CAUTION Set the correct battery type before the first time use SET TYPE BATT PV rs485 can temp batt Auto Recognition and Toggle The Rover Boost requires that the battery bank be 36V or 48V to operate.
Set the Battery Type AGM (Green) is the default battery type for the Rover Boost. To change or set the battery type, long press the SET button for approximately 8 seconds. The Type Indicator will flash a color depending on the battery type indicated below. Tap the SET button to change between battery types until the appropriate TYPE color is flashing. To set the battery type, long press the SET button again and the battery type will be set.
Battery LED Indicator BATT LED Color Behavior Charge State Green Always on Bright, always on Battery is fully charged Yellow Always on Bright, always on Battery voltage is normal Red Always on Bright, always on Battery undervoltage warning Slow Flashing ON 1 second, OFF 1 second, cycle is 2 seconds Quick Flashing ON 0.1 second, OFF 0.1 second, cycle is 0.
CURRENT Current vs. Voltage (12V System) Typical Battery Voltage Range Output Power (48V System) Maximum Power Point 5.88A Battery Voltage Rover Boost Equalize Boost A Bulk Charge B Constant charging C Float Charge Boost Bu lk 58.4V 55.2V Float Recharge 15 17 10 Time VOLTAGE 48V AGM 100W Solar In the chart above, the maximum power point at which the PV module delivers maximum power (17V*5.8A) is observed, and the Rover Boost increases the voltage to Charge an AGM 48V battery bank.
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) .
Lithium Battery Activation The Rover Boost 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.
Host Mode Communication For Renogy Smart Lithium batteries with BMS, the Rover Boost’s RS485/CAN communication ports will be used to synchronize smart battery information and allow up to 2 x Rover Boosts to communicate with each other as separate but paralleled systems to the same battery bank. One controller in the system will be the Host, or the main controller, while the other controller will synchronize its logic to the Host controller.
4.Press and hold the SET button for 20 seconds on the Rover Boost. This will activate the CAN host function and the battery type light will flash once every 5 seconds. Now the controller is communicating and synchronizing the battery recognition information. Rover Boost 1 Ethernet(Cat5 and above)RS485 to CAN RS485 RS485 CAN CAN Smart 48V LFP Battery (Model: RBT50LFP48S) Paralleling 2 Rover Boosts w/ a 48V Smart LFP Battery CAUTION Make sure the polarity is correct.
2.Set the battery type on the host controller, Rover Boost 1. In this case we will select 48V LFP, or purple. 3.Next, run an ethernet cable between the Host controller’s (Rover Boost 1) RS485 communication port to the CAN communication port on the 48V Smart LFP Battery. Rover Boost 1 Rover Boost 2 Ethernet(Cat5 and above)RS485 to CAN RS485 RS485 CAN CAN Smart 48V LFP Battery (Model: RBT50LFP48S) 4.Press and hold the SET button for 20 seconds on Rover Boost 1.
Paralleling 2 Rover Boosts w/ Non-Lithium In Non-lithium batteries, the batteries do not have a BMS and will not be able to communicate synchronization information. Therefore, it is recommended to keep the controller’s distance and wiring the same so the controllers can both detect the same battery bank and connect in parallel. Therefore, the CAN Host function will not be in effect for Non-Lithium batteries. 1.To get started, simply connect both Rover Boost controllers to the same battery bank.
Electronic Protections and Troubleshooting The Rover Boost is equipped with electronic protections to protect the controller and the system. If the Rover Boost is not functioning correctly, it may be undergoing an internal electronic protection. This is not indicative of a defective controller but may require some troubleshooting to resume normal operation mode.
2.Use a multi-meter to verify the correct positive and negative polarity matches the polarity seen on the OUTPUT port. CAUTION Use extra caution when connecting to Lithium batteries. Reverse polarity protection is valid unless there’s PV input source connected. Quick Flashing _ ON 0.1 second, OFF 0.1 second, cycle is 0.2 seconds Battery Overvoltage 3.Toggle the controller by disconnecting and reconnecting the battery to verify the proper system voltage (36V/48V). 4.Check your solar panel input.
PV LED PV _ _ Green Behavior OFF OFF Double Flashing ON 0.1 seconds, OFF 0.1 second, ON 0.1 seconds, OFF 1.7 seconds Protection PV Reverse Polarity PV Overvoltage Lithium Activation Cause / Fix The panels are connected to the controller but not charging or not detected. 1.Use a multi-meter to verify a PV voltage as well as the voltage being within 15 – 40VDC 2.Use a multi-meter to verify the correct positive and negative polarity matches the polarity seen on the OUTPUT port.
More Troubleshooting Behaviors Behavior Probable Cause Cause / Fix The system is dead; no LEDs No battery Power The battery may be experiencing an electronic protection, see disconnected, over-discharged, reverse polarity, over/under temperature in BATT chart above for individual fixes. PV will not display or charge PV Not detected or incorrectly connected The solar panels may be experiencing an electronic protection, see reverse polarity, overvoltage in the PV chart above. 1.
Maintenance Inspect the Rover Boost from time to time to ensure proper performance. For best controller performance: 1.Check the wiring going into the controller from the PV side and BATT side. Make sure there is no wire damage or heavy exposure wear on the wiring 2.Tighten all terminals to ensure a secure connection and avoid added any resistance and heat build-up. 3.Inspect the Rover Bost for any external damage, environmental damage, or corrosion 4.
Technical Specifications Model RCC10RVRB Rated System Voltage 36V / 48V, Auto Recognition (Non-Lithium) Rated Charge Current 10A Battery Operating Range 30 ~ 65 VDC Battery Types AGM, GEL, FLOODED, LFP, USER Rated Max Charge Power PV Input Power: 500W/36V; 650W/48V Charging Power: 450W/36V; 600W/48V Max Input Current (short-circuit, Isc) 35A Power Limiting Protection Up to 600W/36V; 800W/48V Solar Input Voltage Range (VOC) 15 ~ 25VDC @ 36V 15 ~ 40VDC @ 48V MPPT Voltage Range 15 ~ 25VDC @
Battery Charging Parameters Parameter AGM GEL FLD 36V LFP** 48V LFP** USER** Overvoltage Disconnect 16V 16V 16V 44.4V 55.5V 59.2V (27 ~ 68V adjustable) Equalization Voltage --- --- 14.8V --- --- 57.6V (27 ~ 68V adjustable) Boost Voltage 14.6V 14.2V 14.6V Float Voltage 13.8V 13.8V 13.8V --- --- 57.6V (27 ~ 68V adjustable) Boost Recover Voltage 13.2V 13.2V 13.2V 40.8V 50.8V 54.4V (27 ~ 68V adjustable) Undervoltage Recover 12.6V 12.6V 12.6V 38.4V 48V 51.
NOTE By Default, User mode operates as a 48V LFP (16S) battery profile. Each parameter can be individually adjusted to adjust the profile to a 48V User Lithium Charge Profile or a 48V User Non-Lithium Charger Profile. 1. 48V User Lithium batteries will need to indicate the same charging voltage for "Equalization", "Boost Voltage", and "Float Voltage" as the logic will then understand this to mean Lithium. 2.
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