Full Product Manual

4
Four Charging Stages
The Voyager 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.
Boost Charge: When the battery has
charged to the Boost voltage set-point, it
undergoes an absorption stage which is
equivalent to constant voltage regulation to
prevent heating and excessive gassing in the
battery. The default time for this is 120
minutes for the Voyager.
Float Charge: After Boost Charge, 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.
WARNING: Once equalization is active in the battery charging, it will not exit this stage unless
there is adequate charging current from the solar panel. There should be NO load on the batteries
when in equalization charging stage.
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.
WARNING: Equalization may increase battery voltage to a level damaging to sensitive DC loads.
Ensure that all load allowable input voltages are greater than the equalizing charging set point volta