The Traveler Series TM : Voyager 20A PWM Waterproof PWM Controller w/ LCD Displayand LED Bar Version 2.
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 CAUTION NOTE Indicates a potentially dangerous condition.
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 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 deep cycle.
Table of Contents 03 General Information 04 Five Charging Stages 05 Installation 08 Mounting Recommendations 08 Wiring 08 Operation 10 Selecting Battery Type 10 AMP/VOLT Button 10 LED Display 11 LED Behavior 11 LED Error Behavior 12 System Status Troubleshooting 12 Maintenance 13 Fusing 13 Technical Specifications 13 Dimensions 14
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.
Five Charging Stages The Voyager has a 5-stage battery charging algorithm for a 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.
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 Bulk Absorption @ 25°C Equalization Output battery voltage is 3V-10VDC, Current = half of the solar panel current 10VDC to 14VDC Current = Rated Charge Current Constant voltage until current drops to 0.
Identification of Parts (Front) 2 1 3 4 (Back) 5 Key Parts 1. Backlit LCD 2. AMP/VOLT Button 3. BATTERY TYPE Button 4. LED Bar 5. Remote Temperature Sensor Port (optional accessory) 6. Battery Terminals 7.
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. 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.
Distance Wiring Cable Total Length One-Way Distance Cable Size (AWG) NOTE NOTE 09 < 10ft 14-12AWG 10ft-20ft 12-10AWG The solar controller should be installed as near the battery as possible to avoid efficiency loss. 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 setting may damage your battery. Please check your battery manufacturer’s specifications to when selecting battery type.
Normal Sequencing Display V A AH The following is an alternative display voltage for when the battery is Fully charged V LED Display LED Behavior LED Indicators LED Color Soft-start charging Bulk charging ( BV < 11.5V ) Bulk charging ( 11.5V < BV < 12.5V ) BLUE RED ORANGE GREEN ON FLASH ON OFF OFF GREEN OFF ON ON ON OFF OFF OFF ON ON OFF ON OFF OFF Bulk charging ( BV > 12.
LED Error Behavior LED Indicators Error Screen Code LED Color Solar good, BV < 3V Solar good battery reversed RED BLUE ON OFF FLASH RED ORANGE GREEN GREEN OFF OFF OFF ‘b01’ FLASH ON OFF FLASH OFF OFF OFF ‘b02’ FLASH Solar good, battery ON OFF FLASH FLASH FLASH over-voltage Solar off, battery OFF OFF FLASH FLASH FLASH over-voltage Solar good, battery ON OFF FLASH FLASH FLASH over 65°C Battery good, solar FLASH OFF reversed According to BV Battery good, solar FLASH OFF over-voltage Over Temper
Maintenance For best controller performance, it is recommended that these tasks be performed from time to time. 1. Check wiring going into the charge controller and make sure there is no wire damage or wear. 2. Tighten all terminals and inspect any loose, broken, or burnt up connections 3. 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.
Mechanical Parameters Dimensions L6.38 x W3.82 x H1.34 inches Weight Mounting 0.88 lbs. Vertical Wall Mounting IP65 Ingress Protection Rating Maximum Terminals Wire Size Terminals Screw Torque Operating Temperature Meter Operating Temperature Storage Temperature Range Temp. Comp. Coefficient Temp. Comp. Range Operating Humidity 10AWG(5mm2) 13 lbf·in -40°F to +140°F -4°F to +140°F -40°F to +185°F -24mV / °C -4°F ~ 122°F 100% (No condensation) Dimensions 162mm 6.38inch 34mm 1.34inch 97mm 3.
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