Genasun GV-5 User manual

GENASUN GV-5 (ALL MODELS) MANUAL, REVISION 4.1 | 2021
GV-5-Pb-12V: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded
GV-5-Pb-CV: 12 V Custom Multi-Stage Lead-Acid/AGM/Gel/
Sealed/Flooded
GV-5-Li-10.7V (-SP): 9 V (3S) Lithium Iron Phosphate
GV-5-Li-12.5V: 11.1 V (3S) Lithium Cobalt/Manganese/Nickel
GV-5-Li-14.2V: 12 V (4S) Lithium Iron Phosphate
GV-5-Li-16.7V: 14.8 V (4S) Lithium Cobalt/Manganese/Nickel
GV-5-Li-CV: Custom CC/CV or Multi-Stage Lithium
GV-5 Manual
For models:
Solar Charge Controllers with Maximum Power Point Tracking
IMPORTANT SAFETY INSTRUCTIONS | SAVE THESE INSTRUCTIONS
5 A Rated Output
SUNFORGE LLC
2598 FORTUNE WAY • SUITE K
VISTA, CA 92081 • USA
https://sunforgellc.com

This manual contains important instructions for the GV-5-Pb and GV-5-Li solar charge controllers that shall be followed during installation
and maintenance. Various models of the GV-5 are available to charge dierent battery types as follows:
• GV-5-Pb-12V: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded
• GV-5-Pb-CV: 12 V Custom Multi-Stage Lead-Acid/AGM/Gel/Sealed/Flooded
• GV-5-Li-10.7V (-SP): 9 V (3S) Lithium Iron Phosphate
• GV-5-Li-12.5V: 11.1 V (3S) Lithium Cobalt/Manganese/Nickel
• GV-5-Li-14.2V: 12 V (4S) Lithium Iron Phosphate
• GV-5-Li-16.7V: 14.8 V (4S) Lithium Cobalt/Manganese/Nickel
• GV-5-Li-CV(**.*V): Custom CC/CV or Multi-Stage Lithium
• GV-5-Li-PCB CC/CV or Multi-Stage Lithium
• GV-5-Pb-PCB 12 V Multi-Stage Lead-Acid/AGM/Gel/Sealed/Flooded
Consult your battery charging specications to ensure that the GV-5 is compatible with your chosen batteries.
The GV-5 does not include a fuse. Overcurrent protection suitable for the application must be provided by the user.
UL SAFETY AND HAZLOC WARNING: EXPLOSION HAZARD. DO NOT CONNECT OR DISCONNECT WHEN ENERGIZED. DO NOT DISCONNECT WHILE THE CIRCUIT IS
LIVE OR UNLESS THE AREA IS FREE OF IGNITABLE CONCENTRATIONS.
ATTENTION: RISQUE D'EXPLOSION. NE PAS CONNECTER NI DÉCONNECTER PAS LORSQU'IL EST SOUS TENSION. NE PAS CONNECTER LE CIRCUIT ALORS QUE EST
VIVANT OU A MOINS QUE LA ZONE EST LIBRE DE CONCENTRATIONS IGNITAIRES.
CAUTION for the GV-5-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.
Use only 12 V lead-acid batteries with the GV-5-Pb-12 V and GV-5-Pb-CV.
To avoid stress on the GV-5 and possible damage, DO NOT SHORT CIRCUIT the solar array when plugged into the controller, and DO NOT MEASURE SHORT
CIRCUIT CURRENT of the array while connected to the controller.
Grounding is not necessary for operation and is at the user's discretion. If the GV-5 is to be used with a solar array electrically connected to earth ground, please
note the following:
Safety Instructions:

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.
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.
Use only 12 – 30 AWG (3.0 mm2max) 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: 3 –5 in-lbs, 0.35 –0.55 Nm.
LITHIUM WARNING: Use caution when working with lithium systems. Genasun Li controllers use the CC/CV charging prole indicated on the controller. Check the
specications 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 specied 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.
Product Certifications1
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
(1) The GV-5-PCB models are ETL Recognized Components for safety (UL1741).
Inspection & Maintenance
• No user-serviceable parts inside.
• Inspect the controller at least once per year to ensure proper performance.
• Check for animal or insect damage.
• Inspect for corrosion / water damage.
• Inspect the security of all connections.
• Ensure the solar array does not exceed the
maximum input voltage.
• Repair and clean as necessary.

BATTERY LOAD
5 A MAX
PANEL
GV-5
Installation & System Connections:
MOUNTING
Mount the controller near your battery securely using the holes provided on the enclosure’s
anges 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 GV-5 can be mounted in any orientation on the oor 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.
• Do not mount in direct sunlight or near a source of heat.
• Allow adequate airow around the controller to achieve maximum output capability.
• For outdoor use, the controller must be housed in an enclosure providing protection at least
equivalent to NEMA Type 3.
• 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.
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.
The GV-5 has a MULTICOLOR LED. Learn
more about this indicator on page 6.
FUSE
1

LOAD
5 A MAX
Note: Drip loop to protect
charge controller from
water.
CONNECTING THE SOLAR PANEL
Connect the solar panel to the PANEL+ and PANEL- terminals.
• In most applications, the panel should be connected only to the GV-5.
• Never connect the panel negative to the battery negative, as your batteries may be damaged.
Note: In the GV-5, the positive side of the battery is connected internally to the positive side of the solar panel.
• Do not use blocking diodes for single-panel installations. The GV-5 prevents reverse-current ow.
• 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 GV-5 at the coldest possible expected temperature.
• Optional - Genasun Overdrive for Oversized Solar Arrays: The GV-5 can be programmed with adaptivepower-limiting technology
(P/N GV-5-XX-CV), allowing it to be used with solar arrays in excess of its ratedpower. If an oversized array is connected, the GV-5 will
deliver the most power possible while keeping itselectronicsata safetemperaturefor long-term operation. This GV-5 automatically
adjusts fortemperatureand other factorstosmoothly deliverpower at up to 85 °C ambient. If the GV-5 will be used with a solar panel
or array with a short circuit current (Isc) of more than 8 A, the GV-5 input should be protected with a fast-acting fuse or circuit breaker
of 10 A and rated for the maximum solar panel voltage. Note that solar input voltage limits MUST ALWAYS be respected. Exceeding
the input voltage limit will void the warranty and damage the GV-5. For more info about the Genasun Overdrive, please visit the blog
page of our website: https://sunforgellc.com/blog/
34
2
CONNECTING THE LOAD
Connect the load(s) to the LOAD+ and LOAD- terminals.
• The load draw should not exceed 5 A continuous.
• Larger loads should be connected directly to the battery. The GV-5
will not be able to protect the battery against over-discharge (low
voltage disconnect (LVD)) in this case.
CONNECTING THE BATTERY
Connect the battery to the BATT+ and BATT- terminals.
• A small spark while connecting the battery is ok.
CAUTION, RISK OF FIRE OR EXPLOSION: Do not make
the nal battery connection near lead-acid batteries
that have recently been charging.

GREEN LED RUN/CHARGE INDICATION
Standby: The battery is connected properly and ready to charge when
solar panel power is available.
810 SEC. BETWEEN GREEN BLINKS
Charging (low current, less than 0.3 A):
45 SEC. BETWEEN GREEN BLINKS
Charging (between 0.3 A - 3 A):
FAST GREEN BLINKS
Charging (high current, more than 3 A):
LONGER, SLOWER GREEN BLINKS
Charging at current limit: Genasun Overdrive active.
The GV-5 is overloaded and limiting charging current.
LONG, THEN SHORT GREEN BLINKS
Battery charged: The battery is in the absorption or float charging stage.
SOLID GREEN
RED LED ERROR INDICATION
Over-temperature: The controller’s internal temperature is too high.
SETS OF 2 RED BLINKS
Overload: 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 normally due
to low battery voltage. Check the battery connections, wait for the GV-5's
trickle function to charge the battery, or charge the battery by another means.
SETS OF 4 RED BLINKS
SOLID RED
OR OTHER LED INDICATIONS NOT LISTED
Battery voltage too high: If the nominal battery voltage is correct (12 V),
check the functioning of other chargers that may be connected to the system.
SETS OF 5 RED BLINKS
Panel voltage too high: Only 12 V nominal solar panels may be used with this
controller.
SETS OF 6 RED BLINKS
Internal error: Contact your dealer for assistance.
2 LONG BLINKS, FOLLOWED BY ANY NUMBER
OF SHORT BLINKS
The GV-5 has a MULTICOLOR LED.
Status Indication:

Specifications:
Rated Panel Power: 65 W 20 W (-SP) 50 W 55 W 65 W 75 W
(See specs for
closest
Li version.)
Battery Type: 12 V Lead-Acid 3S LiFePO43S Li-ion 4S LiFePO44S Li-ion Custom Voltage
Max Input Voltage: 27 V
Recommended Max Panel Voc at STC: 22 V
Max Input Short Circuit Current:25 A 2 A 5 A 5 A
Max Input Current:39 A 9 A 9 A 9 A
Min Battery Voltage for Normal Operation: 7.2 V
Trickle Charge to Recover Dead (0 V) Battery: Yes
Rated Charging Current: 5 A 2 A 5 A 5 A
Continuous Rated Load Current: 5 A 2 A 5 A 5 A
Tracking Efficiency: 99+% typical
MPPT Tracking Speed: 15 Hz
Electrical Efficiency: 96% – 99.85%
typical 94% – 99.85% typical
Operating Consumption: 0.150 mA (150 uA)
Standby Consumption: 0.125 mA (125 uA)
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 GV-5 battery terminal screws.
• Check the GV-5 terminal area for water or mechanical damage.
The GV-5 will not operate without a battery. If the system appears to be overcharging or the GV-5 will
not begin charging, ensure that the solar panel is wired only to the GV-5, and in particular that the
solar panel negative terminal is not connected to ground (battery negative). For more in-depth system
troubleshooting, please visit the support area of our website: https://sunforgellc.com/learning-center
(2) Panel Isc. Inputs exceeding this rating may cause damage to the GV-5 if the input or battery voltage changes abruptly.
(3) Maximum steady-state current that the controller could draw from an unlimited source. This specication is intended for sizing input circuit protection.
Pb-12V Li-10.7V-SP Li-CVLi-12.5V Li-16.7VLi-14.2VMODEL (GV-5-**) Li-10.7V

Specifications (cont.):
Charge Profile:
Multi-Stage
with Temperature
Compensation
CC-CV CC/CV or
Multi-Stage
Bulk Voltage: 14.4 V –
Absorption Voltage: 14.2 V –
Absorption Time: 2 hours –
Float Voltage (Pb models) or
CV Voltage (Li models): 13.5 V 10.5 V 12.5 V 14.2 V 16.7 V Custom Voltage
Re-Absorb (Re-Bulk):412.5 V –
Load Disconnect (LVD)/Reconnect Voltage: 11.4 V / 12.5 V 8.2 V / 9.0 V 9.3 V / 10.5 V 11.0V / 12.0 V 12.4 V / 14.0 V Custom Voltage
Battery Temperature Compensation: -28 mV/°C
(referred to 25 °C) Disabled
Operating Temperature: -40 °C – 85 °C
Max Full Power Operating Ambient:545 °C
Connection: 6-position terminal block for 12 –30 AWG wire
Weight:62.8 oz (80 g)
Dimensions:64.3" x 2.2" x 1.14" (11 cm x 5.6 cm x 2.9 cm)
Environmental Protection:6IP40, Conformal Coating, Nickel-Plated Brass & Stainless Hardware
Certifications: CE, FCC, RoHS
Warranty: 10 years
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.
(4) If the battery voltage drops below this point, the controller will attempt to run an absorption cycle. Otherwise, it will charge to the oat voltage.
(5) Max ambient temperature for full operating power. Test conditions: 16 V input, 13 V output, GV-5 vertically (wall) mounted.
(6) This specication does not apply to GV-5-PCB. Specications for the GV-5-PCB are as follows: Weight: 0.8 oz (23 g); Dimensions: 3.3" x 1.9" x 0.9" (8.3 cm x 4.8 cm x 2.3 cm); Environmental Protection: IP00.
Pb-12V Li-10.7V(-SP) Li-CVLi-12.5V Li-16.7VLi-14.2VMODEL (GV-5-**)