Genasun GV-Boost User manual

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-Li-**.*V: Custom Lithium Variation
GV-Boost Manual
For models:
Solar Charge Controllers with Maximum Power Point Tracking
IMPORTANT SAFETY INSTRUCTIONS | SAVE THESE INSTRUCTIONS
GENASUN GV-BOOST(ALL MODELS) MANUAL, REVISION 1.0 | 10.2012
8A Input / 105-350W
http://genasun.com
GENASUN INC.
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This manual contains important instructions for the GV-Boost GVB-8-Pb-**V and GVB-8-Li-**.*V solar charge controllers that shall
be followed during installation and maintenance. Various models of the GVB are available to charge dierent battery types as follows:
• 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-Li-**.*V: Custom Lithium Variation
Consult your battery charging specifications to ensure that the GVB is compatible with your chosen batteries.
Carefully follow these instructions.
CAUTION for the GVB-8-Pb-**V(Lead-Acid Versions Only):
INTERNAL TEMPERATURE COMPENSATION. RISK OF FIRE, USE WITHIN 0.3 m (1 ft) 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 will DESTROY the controller, and such damage will not be covered under warranty.
LITHIUM WARNING: Take 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.
Safety Instructions: LITHIUM BMS WARNING: Genasun recommends using a lithium battery with a Battery Management System 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 systems.
Use only 10-30 AWG copper conductors suitable for a minimum of 60 degrees C. If operation at high power or at high ambient
temperatures is expected, wire with a higher temperature rating may be necessary.
Inspection & Maintenance
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 PANEL
GV-Boost
Installation & System Connections:
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 battery.
 The GVB can be mounted in any orientation.
 Do not expose to water (PLEASE SEE MODEL GVB-WP FOR WATERPROOF VERSION).
 Do not mount in direct sunlight or near a source of heat.
 Allow adequate airflow 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.
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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 GVB.
 The LED may blink red until a battery is connected.
 Do not use blocking diodes for single-panel installations. The GVB 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 at the
coldest possible expected temperature.
• 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.
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 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.
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Note: Do not install this controller in a Golf Cart. Genasun Oers the GVB-WP for Golf
Carts and other applications where water resistance is needed.
Note: Make sure to inspect the controller at least once per year to ensure proper
performance. Please see the Inspection & Maintenance section in this guide.
The GVB has a
MULTICOLOR LED.
Learn about this indicator
on the following page.

Troubleshooting
If the LED indicator does not light with a battery connected, or blinks the over-battery-voltage
error, or the controller does not charge, the internal fuse may be blown. Check the fuse inside
the GVB by removing the four screws on the bottom of the enclosure. If the fuse is blown,
replace it with a 10A fast-acting ATO or ATC fuse rated for the maximum battery voltage.
Automotive-style fuses are typically rated to 32V, and are suitable for the GVB-8-Pb-12V, GVB-
8-Pb-24V, and lithium models with a CV voltage up to 31V (i.e., GVB-8-Li-31.0V. For the GVB-8-
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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 ~3.5A):
FAST & SHORT BLINKS
Charging (high current, input current more than ~3.5A):
LONGER BLINKS
Charging (current limit): charging at current limit.
The GVB is overloaded and limiting input current. Check that the
solar panel rating is within the GVB’s input specifications.
LONG, THEN SHORT BLINKS
Battery Charged: The battery is in the absorption
or float charging stage.
SOLID LED
LED ERROR INDICATION
Overheat: The controller’s internal temperature is too high.
SETS OF 2 RED BLINKS.
Overload: The GVB 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 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.
The GVB has a MULTICOLOR LED
Status Indication:
Specifications:
The most common causes of blown fuses are:
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charging. In this case, there may be other internal
damage to the controller.
Marine Grade: Yes Yes
Waterproof: NO NO (See Genasun Model GVB-WP) NO (See Genasun
Model GVB-WP)
Connection: 4-position terminal block for 10-30AWG wire
Weight: 6.5oz., 185g
Dimensions: 5.5x2.5x1.2”, 14x6.5x3.1cm
Warranty: 5 years
GVB-8-Pb-12V GVB-8-Pb-24V GVB-8-Pb-36V GVB-8-Pb-48V GVB-8-Li-**.*V

Copyright © 2012 Genasun. All rights reserved. Changes are periodically made to the information herein which will be incorporated in revised editions
of this publication. Genasun may make changes or improvements to the product(s) described in this publication at any time and without notice.
Specifications(cont.): GVB-8-Pb-12V GVB-8-Pb-24V GVB-8-Pb-36V GVB-8-Pb-48V GVB-8-Li-**.*V
Rated Panel (Input) Current: 8A 8A
Minimum Panel Voltage for Charging: 5V 5V
Minimum Battery Voltage for Operation: 9.5V 9.5V
Absolute Maximum Panel Open-Circuit
Voltage (Voc): 63V 63V
Charge Profile: Multi-Stage with Temperature Compensation CC-CV
Nominal Battery Voltage: 12V 24V 36V 48V
(See specs for
closest -Pb
equivalent.)
Maximum Recommended Panel Vmp: 13V 26V 41V 43V
Maximum Recommended Panel Power
(8A Panel w/~155mm cells): 105W 210W 325W 350W
Bulk Voltage: 14.4V 28.8V 43.2V 57.6V –
Absorption Voltage: 14.2V 28.4V 42.6V 56.8V –
Absorption Time: 2 Hours –
Float Voltage (Pb models) or
CV Voltage (Li models): 13.8V 27.6V 41.4V 55.2V **.*V as specified in part number
Battery Temperature Compensation: -28mV/°C -56mV/°C -84mV/°C -112mV/°C –
Electrical Efficiency: 95% - 97% typical 96% - 98% typical 96% - 98% typical 96% - 99% typical (See specs for
closest -Pb
equivalent.)
Night Consumption: 7mA 6mA 6mA 5mA
Tracking Efficiency: 99+% typical 99+% typical
MPPT Tracking Speed: 15Hz 15Hz