User Manual for GENASUN models including: GVB-8-Pb-12V MPPT Solar Charge Controller for Lithium, GVB-8-Pb-12V, MPPT Solar Charge Controller for Lithium, Charge Controller for Lithium, Controller for Lithium, Lithium
Troubleshooting If the LED Indicator will not light, or displays an indication not listed in this manual: • Verify correct battery polarity. • Check that there is a solid electrical connection to the battery.
GVB-8 (Boost) Manual Solar Charge Controllers with Maximum Power Point Tracking For models: GVB-8-Pb-12V: 12V Lead-Acid/AGM/Gel/Sealed/Flooded GVB-8-Pb-24V: 24V Lead-Acid/AGM/Gel/Sealed/Flooded GVB-8-Pb-36V: 36V Lead-Acid/AGM/Gel/Sealed/Flooded GVB-8-Pb-48V: 48V Lead-Acid/AGM/Gel/Sealed/Flooded GVB-8-Pb-CV: Custom Multi-Stage Lead-Acid/AGM/Gel/ Sealed/Flooded GVB-8-Li-14.2V: 12V (4S) Lithium Iron Phosphate GVB-8-Li-25.0V: 24V (6S) Lithium Cobalt/Manganese/Nickel GVB-8-Li-28.4V: 24V (8S) Lithium Iron Phosphate GVB-8-Li-41.7V: 36V (10S) Lithium Cobalt/Manganese/Nickel GVB-8-Li-56.8V: 48V (16S) Lithium Iron Phosphate GVB-8-Li-CV: Custom CC/CV or Multi-Stage Lithium Variation SUNFORGE LLC 2598 FORTUNE WAY · SUITE K VISTA, CA 92081 · USA ht tps: //sunfo rg e llc .c o m 8A Input - 105W / 210W / 325W / 350W GENASUN GVB-8 BOOST (ALL MODELS) MANUAL, REVISION 4.1 | 2021 IMPORTANT SAFETY INSTRUCTIONS | SAVE THESE INSTRUCTIONS Safety Instructions: This manual contains important instructions for the GVB-8 Boost (GVB-8-Pb and GVB-8-Li) solar charge controllers that shall be followed during installation and maintenance. Various models of the GVB-8 are available to charge different battery types as follows: · GVB-8-Pb-12V: 12V Lead-Acid/AGM/Gel/Sealed/Flooded · GVB-8-Li-14.2V: · GVB-8-Pb-24V: 24V Lead-Acid/AGM/Gel/Sealed/Flooded · GVB-8-Li-25.0V: · GVB-8-Pb-36V: 36V Lead-Acid/AGM/Gel/Sealed/Flooded · GVB-8-Li-28.4V: · GVB-8-Pb-48V: 48V Lead-Acid/AGM/Gel/Sealed/Flooded · GVB-8-Li-41.7V: · GVB-8-Pb-CV: Custom Lead-Acid/AGM/Gel/Sealed/Flooded · GVB-8-Li-56.8V: · GVB-8-Pb-PCB: Multi-Stage Lead-Acid/AGM/Gel/Sealed/Flooded · GVB-8-Li-CV: · GVB-8-Li-PCB 12V (4S) Lithium Iron Phosphate 24V (6S) Lithium Cobalt/Manganese/Nickel 24V (8S) Lithium Iron Phosphate 36V (10S) Lithium Cobalt/Manganese/Nickel 48V (16S) Lithium Iron Phosphate Custom CC/CV or Multi-Stage Lithium CC/CV or Multi-Stage Lithium Consult your battery charging specifications to ensure that the GVB-8 is compatible with your chosen batteries. The GVB-8 includes a 10A fast-acting ATO fuse rated for the maximum battery voltage. UL SAFETY AND HAZLOC WARNING: EXPLOSION HAZARD. DO NOT SERVICE, CONNECT, DISCONNECT, OR CHANGE FUSES UNLESS THE AREA IS FREE OF IGNITABLE CONCENTRATIONS. ATTENTION: RISQUE D'EXPLOSION. NE PAS RÉPARER, CONNECTER, DÉCONNECTER, OU REMPLACER LES FUSIBLES À MOINS QUE LA ZONE SOIT EXEMPTE DE CONCENTRATIONS INFLAMMABLES. WARNING: REPLACE ONLY WITH THE SAME RATINGS AND TYPE OF FUSE. DISCONNECT ALL SOURCES OF SUPPLY BEFORE SERVICING. NON-ISOLATED. ONLY VERSIONS WITH VOLTAGE ABOVE 42.4 V - WHEN A GROUND FAULT IS INDICATED, BATTERY TERMINALS AND CONNECTED CIRCUITS MAY BE UNGROUNDED AND HAZARDOUS. ATTENTION: REMPLACER SEULEMENT AVEC LE MÊME TYPE ET VALEUR NOMINALE DE FUSIBLE. DÉBRANCHER TOUTES LES SOURCES D'ALIMENTATION AVANT L'ENTRETIEN. PAS ISOLÉ. SEULES LES VERSIONS DE TENSION SUPÉRIEURES À 42,4 V - LORSQU'UN DÉFAUT À LA TERRE EST INDIQUÉ, LES BORNES DE BATTERIE ET LES CIRCUITS CONNECTÉS PEUVENT ÊTRE N'EST PAS RELIÉE À LA TERRE ET DANGEREUX. CAUTION for the GVB-8-Pb (Lead-Acid Versions Only): INTERNAL TEMPERATURE COMPENSATION. RISK OF FIRE, USE WITHIN 1 ft (0.3 m) of BATTERIES. Lead-acid batteries can create explosive gases. Short circuits can draw thousands of amps from a battery. Carefully read and follow all instructions supplied with the battery. DO NOT SHORT CIRCUIT the solar array when plugged into the controller. DO NOT MEASURE SHORT CIRCUIT CURRENT of the array while connected to the controller. This may damage the controller, and such damage will not be covered under warranty. Grounding is not necessary for operation and is at the user's discretion. If the GVB-8 is to be used with a solar array electrically connected to earth ground, please note the following: WARNING: THIS UNIT IS NOT PROVIDED WITH A GFDI DEVICE. Consult Article 690 of the National Electrical Code (or the standards in force at the installation location) to determine whether a GFDI is necessary for your installation. Use only 10 30 AWG (5.0 mm2 max) copper conductors suitable for a minimum of 60 o C. If operation at high power or at high ambient temperatures is expected, wire with a higher temperature rating may be necessary. Recommended terminal block tightening torque: 7 in-lbs, 0.79 Nm. WARNING: THIS UNIT IS NOT PROVIDED WITH DISCONNECT DEVICES. Consult Article 690 of the National Electrical Code (or the standards in force at the installation location) to determine whether disconnect devices are necessary for your installation. LITHIUM WARNING: Use caution when working with lithium systems. Genasun Li controllers use the CC/CV charging profile indicated on the controller. Check the specifications of the battery pack to ensure that the CV voltage is correct. Further check that the power supplied by the solar array and Genasun controller is within the battery specified design limits. LITHIUM BMS WARNING: Genasun recommends using a lithium battery with a Battery Management System (BMS) capable of disconnecting the solar charge controller in the event that any cell in the pack is outside of its rated temperature, current, or voltage range. Failure to do so may result in property damage, injury or death. Genasun highly recommends the use of a BMS with cell balancing. Cell balancing is mandatory for lithium iron phosphate. Inspection & Maintenance · Inspect the controller at least once per year to ensure proper performance. · Inspect the security of all connections. · Check for animal or insect damage. · Ensure the solar array does not exceed the maximum input voltage. · Inspect for corrosion / water damage. · Repair and clean as necessary. Product Certifications1 Safety Conforms to: UL STD 1741 Certified to: CSA STD C22.2#107.1 HazLoc (C1D2) Conforms to: UL STD 121201 Certified to: CSA STD C22.2#213 (1) The GVB-8-PCB models are ETL Recognized Components for safety (UL1741). EMC Conforms to: EN 61000-6-3:2007+A1:2011 EN 61000-6-2:2005 AS/NZS 61000-6-3:2012 EMC Conforms to: FCC (CFR Title 47) Part 15 Radio frequency Devices, Subpart B - Unintentional Radiators. Tested for compliance. Restriction of Hazardous Substances Conforms to: EN 50581:2012 Installation & System Connections: · Connections should be made according to Article 690 of the National Electrical Code (NFPA 70) or the standards in force at the installation location. · Electrical connections may be made in any order; however the sequence below is recommended. 1 MOUNTING Mount the controller near your battery securely using the holes provided on the enclosure's flanges or with a means appropriate to the application. · Mount near the battery (for lead-acid versions only, use within 1 ft (0.3 m) of batteries. See Caution, p.2). · The GVB-8 can be mounted in any orientation on the floor or wall. We recommend a position in which all labels are clearly visible. Although the GV can be used in any orientation, for marine or other applications where liquid water may be nearby, the GV should be mounted with the terminal block down (or where not possible, to the side). This orientation facilitates the use of drip loops to prevent liquid water from running along the wiring into the controller. · Do not expose to water (PLEASE SEE MODEL GVB-8-WP FOR WATERPROOF VERSION). · Do not mount in direct sunlight or near a source of heat. · Allow adequate airflow around the controller. · For versions above 42.4 V, apply the sticker provided in the box on or adjacent to the battery. · For outdoor use, the controller must be housed in an enclosure providing protection at least equivalent to NEMA Type 3. Note: Do not install this controller in a Golf Cart. Genasun offers the GVB-8-WP for Golf Carts and other applications where water resistance is needed. Note: The positive or negative battery cable must be protected by a fast-acting fuse or circuit breaker of 10 A or less, rated for the maximum battery voltage and connected close to the battery terminal or power distribution block. This fuse will protect the wiring in the event of a short circuit or controller damage. BATTERY PANEL FUSE GVB-8(Boost) 2 CONNECTING THE SOLAR PANEL Connect the solar panel to the PANEL+ and PANEL- terminals. While connecting the battery first will not damage the GVB-8, we recommend connecting the panel first. This eliminates the risk of shortcircuiting the panel while the GVB-8 is operating, which can cause damage. · In most applications, the panel should be connected only to the GVB-8. · The LED may blink red until a battery is connected. · Do not use blocking diodes for single-panel installations. The GVB-8 prevents reverse-current flow. · If multiple panels are being used in parallel, blocking diodes are recommended in series with each panel, unless the panel manufacturer recommends otherwise. · Solar panel voltage rises in cold weather. Check that the solar panel open circuit voltage (Voc) will remain below the maximum input voltage of the GVB-8 at the coldest possible expected temperature. Note: In the GVB-8, the negative side of the battery is connected internally to the negative side of the solar panel. The GVB-8 has a MULTICOLOR LED. Learn about this indicator on the following page. Note: Drip loop to protect charge controller from water. 3 CONNECTING THE BATTERY Connect the battery to the BATT+ and BATT- terminals. · A small spark while connecting the battery is ok. · Any loads should be connected directly to the battery. The GVB-8 does not provide protection against over-discharge. CAUTION, RISK OF FIRE OR EXPLOSION: Do not make the final battery connection near lead acid batteries that have recently been charging. Status Indication: The GVB-8 has a MULTICOLOR LED. LED RUN/CHARGE INDICATION Standby: The battery is connected properly and ready to charge when solar panel power is available. 2 SEC. BETWEEN BLINKS Charging (low current, input current less than ~3.5 A): FAST & SHORT BLINKS Charging (high current, input current more than ~3.5 A): LONGER, SLOWER BLINKS Charging at current limit: The GVB-8 is overloaded and limiting input current. Check that the solar panel rating is within the GVB-8's input specifications. LONG, THEN SHORT BLINKS Battery charged: The battery is in the absorption or float charging stage. SOLID LED LED ERROR INDICATION Over-temperature: The controller's internal temperature is too high. SETS OF 2 RED BLINKS Overload: The GVB-8 has been overloaded. This could be caused by changing the solar panel connections while the controller is operating. SETS OF 3 RED BLINKS Battery voltage too low: The controller cannot begin charging due to low battery voltage. Charge the battery by some other means before use. SETS OF 4 RED BLINKS Battery voltage too high: Check that the correct GVB-8 has been selected for the nominal system battery voltage. If the nominal battery voltage is correct, check the functioning of other chargers that may be connected to the system. This error can also be caused by a disconnected battery or blown fuse. SETS OF 5 RED BLINKS Internal error: Contact your dealer for assistance. 2 LONG BLINKS, FOLLOWED BY ANY NUMBER OF SHORT BLINKS Troubleshooting If the LED Indicator will not light, or displays an indication not listed in this manual: · Verify correct battery polarity. · Check that there is a solid electrical connection to the battery. · Check that battery voltage appears on the GVB-8 battery terminal screws. Note: The most common causes of blown fuses are: · Connecting the GVB-8 to the battery backwards. · Shorting the solar panel input while the GVB-8 is charging. In this case, there may be internal damage to the controller. · Check the 10 A fuse inside the GVB-8. · Check the GVB-8 terminal area for water or mechanical damage. The GVB-8 will not operate without a battery. If the system appears to be overcharging or the GVB-8 will not begin charging, ensure that the solar panel is wired only to the GVB-8. If the GVB-8 does not appear to be charging, note that the GVB-8 waits up to one minute before trying to restart if is has shut down due to lack of power from the solar panel. Check the fuse inside the GVB-8 by removing the four screws on the bottom of the enclosure. If the fuse is blown, replace it with a 10 A fast-acting ATO or ATC fuse rated for the maximum battery voltage. Automotive- style fuses are typically rated to 32 V, and are suitable for the GVB-8-Pb-12V, GVB-8-Pb-24V, and lithium models with a CV voltage up to 31 V (i.e., GVB-8-Li-CV at 31.0 V). For the GVB-8-Pb-36V, GVB-8-Pb-48V, and higher-voltage lithium models, a fuse with a higher voltage rating is required. We recommend Optifuse part number APR58-UL, rated to 58 V. For more in-depth system troubleshooting, please visit the support area of our website: https://sunforgellc.com/learning-center/ Specifications: GVB-8, All Models Rated Panel (Input) Current:2 8A Min Panel Voltage for Charging: 5V Min Battery Voltage for Operation: 9.5V Trickle Charge to Recover Dead (0V) Battery Yes Max Input (Panel) Voltage: 60V Recommended Max Panel Voc at STC: 50V Input Voltage Range: 0 60V Max Input Short Circuit Current:2,3 8A Max Input Current:4 15A MPPT Tracking Speed: 15Hz Operating Temperature: -40 °C 85 °C Max Full Power Operating Ambient:5 70 °C Warranty: 5 years Connection: 4-position terminal block for 10 30AWG wire Certifications: cETLus, CE, FCC, RoHS (2) Panel ratings have increased since we designed the GVB-8. Although we don't believe in changing specifications without a corresponding engineering change, based on both our customers' experiences over the years as well as the headroom we designed into the GVB-8, we feel comfortable recommending the GVB-8 for panels with Imp up to 9 A. (3) Panel Isc. Max input power and maximum input voltage requirements must also be respected. (4) Max current that the controller could draw from an unlimited source. This specification is not intended for determining PV input. (5) Max ambient temperature for full operating power. Specifications (cont.): Weight:6 GVB-8, All Models 6.5oz (185g) Dimensions:6 5.4" x 2.4" x 1.3" (13.7 cm x 6.2 cm x 3.3 cm) Environmental Protection:6 GVB-8-Pb-12V IP40, Nickel-Plated Brass & Stainless Hardware GVB-8-Pb-24V GVB-8-Pb-36V GVB-8-Pb-48V GVB-8-Pb-CV Max Recommended Panel Power (8A Panel w/~155mm cells): 105W 210W 325W 350W Max Recommended Panel Vmp: 13V 26V 41V 43V Nominal Battery Voltage: 12V 24V 36V 48V Charge Profile: Multi-Stage with Temperature Compensation Bulk Voltage: 14.4V 28.8V 43.2V 57.6V Absorption Voltage: Absorption Time: 14.2V 28.4V 2 Hours 42.6V 56.8V (See specs for closest Pb equivalent.) Float Voltage: Re-Absorb (Re-Bulk):7 13.8V 12.5 V 27.6V 25 V 41.4V 37.5 V 55.2V 50 V Battery Temperature Compensation (referred to 25 °C): -28mV/°C -56mV/°C -84mV/°C -112mV/°C Electrical Efficiency: 95% - 97% typical 96% - 98% typical 96% - 98% typical 96% - 99% typical Standby Consumption: 7mA 6mA 6mA 5mA Battery type: Max Recommended Panel Vmp: GVB-8-Li-14.2V 4S LiFePO4 13V GVB-8-Li-25.0V 6S Li-ion 20 V GVB-8-Li-28.4V 8S LiFePO4 26V GVB-8-Li-41.7V 10S Li-ion 39V GVB-8-Li-56.8V 16S LiFePO4 43V GVB-8-Li-CV Lithium Max Recommended Panel Power: Electrical Efficiency: 105W 95% - 97% typical 210 W 95% - 97% typical 210W 96% - 98% typical 325W 96% - 98% typical 350W 96% - 99% typical (See specs for closest CC/CV voltage.) Standby Consumption: 7mA 6mA 6mA 6mA 5mA Charge Profile: CC/CV CC/CV or Multi-Stage CV Voltage: 14.2V 25.0 V 28.4V 41.7V 56.8V Custom Voltage Battery Temperature Compensation: Disabled (6) This specification does not apply to the GVB-8-PCB. The specifications for the GVB-8-PCB are as follows: Weight: 3.8oz (108 g); Dimensions: 4.8" x 2.2" x 1.1" (12cm x 5.5cm x 2.7 cm); Environmental Protection: IP00. (7) If the battery voltage drops below this point, the controller will attempt to run an absorption cycle. Otherwise, it will charge to the float voltage. Copyright © 2021 Sunforge LLC. All rights reserved. Changes are periodically made to the information herein which will be incorporated in revised editions of this publication. Sunforge may make changes or improvements to the product(s) described in this publication at any time and without notice.Adobe PDF Library 17.0 Adobe InDesign 19.0 (Windows)