Sunforge Genasun gvb-8-wp series User manual

GVB-8-Pb-12V-WP: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded

GVB-8-Pb-24V-WP: 24 V Lead-Acid/AGM/Gel/Sealed/Flooded

GVB-8-Pb-36V-WP: 36 V Lead-Acid/AGM/Gel/Sealed/Flooded

GVB-8-Pb-48V-WP: 48 V Lead-Acid/AGM/Gel/Sealed/Flooded

GVB-8-Li-14.2V-WP: 12 V (4s) Lithium Iron Phosphate

GVB-8-Li-28.4V-WP: 24 V (8s) Lithium Iron Phosphate

GVB-8-Li-41.7V-WP: 36 V (10s) Lithium Cobalt/Manganese/Nickel

GVB-8-Li-42.6V-WP: 36 V (12S) Lithium Iron Phosphate

GVB-8-Li-50.0V-WP: 36 V (12s) Lithium Cobalt/Manganese/Nickel

GVB-8-Li-54.2V-WP: 48 V (13s) Lithium Cobalt/Manganese/Nickel

GVB-8-Li-56.8V-WP: 48 V (16s) Lithium Iron Phosphate

GVB-8-Li-58.4V-WP: 52 V (14s) Lithium Cobalt/Manganese/Nickel

GVB-8-WP (Boost) Manual

For models:

Waterproof Voltage Boosting Solar Charge Controllers with

Maximum Power Point Tracking

IMPORTANT SAFETY INSTRUCTIONS | SAVE THESE INSTRUCTIONS

GENASUN GVB-8-WP BOOST (ALL MODELS STARTING FROM S/N 188100) MANUAL, REVISION 7.0 | 2024

8A Input - 105 W / 210 W / 325 W / 350 W

SUNFORGE LLC

2598 FORTUNE WAY • SUITE K

VISTA, CA 92081 • USA

https://sunforgellc.com

This manual contains important instructions for the GVB-8-WP Boost (all versions starting from S/N 188100) solar charge controllers that shall

be followed during installation and maintenance. Various models of the GVB-8-WP are available to charge dierent battery types as follows:

• GVB-8-Pb-12V-WP: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded

• GVB-8-Pb-24V-WP: 24 V Lead-Acid/AGM/Gel/Sealed/Flooded

• GVB-8-Pb-36V-WP: 36 V Lead-Acid/AGM/Gel/Sealed/Floode

• GVB-8-Pb-48V-WP: 48 V Lead-Acid/AGM/Gel/Sealed/Flooded

• GVB-8-Li-14.2V-WP: 12 V (4S) Lithium Iron Phosphate

• GVB-8-Li-24.8V-WP: 24 V (8S) Lithium Iron Phosphate

Consult your battery charging specications to ensure that the GVB-8-WP is compatible with your chosen batteries.

The GVB-8-WP includes an external 10 A In-Line fuse rated for the maximum battery voltage.

WARNING: EXPLOSION HAZARD. DO NOT CONNECT OR DISCONNECT WHEN ENERGIZED. DO NOT REMOVE OR REPLACE FUSES UNLESS POWER

HAS BEEN DISCONNECTED OR THE AREA IS FREE OF IGNITIBLE CONCENTRATIONS. ATTENTION: RISQUE D'EXPLOSION. NE PAS CONNECTER NI

DÉCONNECTER PAS LORSQU'IL EST SOUSTENSION. NE PAS CONNECTER LE CIRCUIT ALORS QUE EST VIVANT OU A MOINS QUE LA ZONE EST LIBRE

DE CONCENTRATIONS IGNITAIRES. CAUTION for the GVB-8-Pb-**V-WP (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 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-WP 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.

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.

Safety Instructions:

• GVB-8-Li-41.7V-WP: 36 V (10S) Lithium Cobalt/Manganese/Nickel

• GVB-8-Li-42.6V-WP: 36 V (12S) Lithium Iron Phosphate

• GVB-8-Li-50.0V-WP: 36 V (12S) Lithium Cobalt/ Manganese/Nickel

• GVB-8-Li-54.2V-WP: 48 V (13S) Lithium Cobalt/ Manganese/Nickel

• GVB-8-Li-56.8V-WP: 48 V (16S) Lithium Iron Phosphate

• GVB-8-Li-58.4V-WP: 52 V (14S) Lithium Cobalt/ Manganese/Nickel

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 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. Use only copper conductors suitable for a minimum of 60 °C. If operation at high power or at high ambient temperatures is expected,

wire with a higher temperature rating may be necessary.

Product Certifications

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 Hazardous Substances

Conforms to:

EN 50581:2012

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.

10 A IN-LINE FUSE

(INCLUDED)

VOLTAGE BOOSTING MPPT SOLAR CHARGE CONTROLLER

PANEL

BATT

MAX

COMMON

Note:Note: Starting from S/N 188100 the GVB-8-WP

(all models) comes with 12 AWG ying leads.

For the previous version, please refer to manual

revision 6.0 |2021

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 0.3 m (1 ft) of batteries. See Caution, p.2).

• The GVB-8-WP can be mounted in any orientation on the oor or wall. We recommend a position in which all

labels are clearly visible.

• Do not mount in direct sunlight or near a source of heat.

• Allow adequate airow around the controller to achieve maximum output capability.

• 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.

Note:Note: GVB-8-WP is Negative Common,

"-Panel" and "-Battery" (both black cables)

are interchangeble.

PANEL BATTERY

GVB-8-WP (Boost)

VOLTAGE BOOSTING MPPT SOLAR CHARGE CONTROLLER

*FUSE

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-8-WP.

• The LED may blink red until a battery is connected.

• Do not use blocking diodes for single-panel installations. The GVB-8-WP 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 GVB-8-WP at the coldest possible

expected temperature.

Note: In the GVB-8-WP, the negative side of the battery is connected internally to the

negative side of the solar panel.

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-WP does not provide

protection against over-discharge.

CAUTION, RISK OF FIRE OR EXPLOSION: Do not make the nal battery connection near

lead-acid batteries that have recently been charging.

The GVB-WP has a

MULTICOLOR LED.

Learn about this indicator

on the following page.

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 (current limit): charging at current limit.

The GVB-8-WP is overloaded and limiting input current. Check that the

solar panel rating is within the GVB-8-WP’s input specifications.

LONG, THEN SHORT BLINKS

Battery Charged: The battery is in the absorption

or float charging stage.

SOLID GREEN

LED ERROR INDICATION

Overheat: The controller’s internal temperature is too high.

SETS OF 2 RED BLINKS

Overload: The GVB-8-WP 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 high: Check that the correct GVB-8-WP 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

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

SOLID RED

OR OTHER LED INDICATIONS NOT LISTED

The GVB has a MULTICOLOR LED

Status Indication:

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-WP battery cables.

The GVB-8-WP will not operate without a battery. If the system appears to be overcharging or the GVB-8-WP will not begin charging, ensure that the solar panel is wired only to the GVB-8-WP.

If the GVB-8-WP does not appear to be charging, note that the GVB-8-WP waits up to one minute before trying to restart if is has shut down due to lack of power from the solar panel. If the

LED indicator will not light with a battery connected, or blinks the over-battery-voltage error, or the controller does not charge, the fuse may be blown. The GVB-8-WP fuse is located in a black

waterproof in-line fuse holder in the positive battery line. 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-WP, GVB-8-Pb-24V-WP, GVB-8-Li-14.2V-WP, and GVB-8-Li-28.4V-WP. For versions 36 V and 48 V nominal, a fuse with a higher

voltage rating is required. We recommend Optifuse part number APR58-UL-10A, rated 10 A / 58 V. For more in-depth system troubleshooting, please visit the support area of our website:

https://sunforgellc.com/learning-center.

Specifications:

Rated Panel (Input) Current:18 A

Minimum Panel Voltage for Charging: 5 V

Minimum Battery Voltage for Operation: 9.5 V

Trickle Charge to Recover Dead (0V) Battery: Yes

Maximum Input Panel: 60 V

Recommended Max Panel Voc at STC: 50 V

Input Voltage Range: 0-60 V

Maximum Input Short Circuit Current:28 A

Maximum Input Current:315 A

Operating Temperature: -40 °C – 85 °C

Maximum Full Power Ambient: 50 °C

MPPT Tracking Speed: 15 Hz

Environmental Protection: IP68, Waterproof

Connection:4Flying Leads, 12 AWG tinned wire, pre-stripped

GVB-8-WP, All Models

Note: The most common causes of blown fuses are:

• Connecting the GVB-8-WP to the battery backwards;

• Shorting the solar panel input while the GVB-8-WP is charging. In this case,

there may be internal damage to the controller.

(1) Panel ratings have increased since we designed the GVB-8-WP. Although we don't believe in changing specications 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-WP, we feel comfortable recommending the GVB-8-WP for panels with Imp up to 9 A.

(2) Panel Isc. Maximum input power and maximum input voltage requirements must also be respected.

(3) Maximum current that the controller could draw from an unlimited source.This specication is not intended for determining PV input.

(4) Starting from S/N 188100, ying leads are 12 AWG instead of 16 AWG. For the previous version, please refer to manual revision 6.0 | 2021.

changes or improvements to the product(s) described in this publication at any time and without notice.

Specifications (cont.):

GVB-8-Pb-12V-WP GVB-8-Pb-24V-WP GVB-8-Pb-36V-WP GVB-8-Pb-48V-WP

Charge Prole: Multi-Stage with Temperature Compensation

Nominal Battery Voltage: 12 V 24 V 36 V 48 V

Maximum Recommended Panel Vmp: 13 V 26 V 41 V 43 V

Maximum Recommended Panel Power (8A Panel w/~155mm cells): 105 W 210 W 325 W 350 W

Bulk Voltage: 14.4 V 28.8 V 43.2 V 57.6 V

Absorption Voltage: 14.2 V 28.4 V 42.6 V 56.8 V

Absorption Time: 2 Hours

Float Voltage:513.3 V 26.6 V 39.9 V 53.2 V

Re-Absorb (Re-Bulk):612.5 V 25 V 37.5 V 50 V

Battery Temperature Compensation (referred to 25 °C): -28 mV/°C -56 mV/°C -84 mV/°C -112 mV/°C

Electrical Eciency: 95% - 97% typical 96% - 98% typical 96% - 98% typical 96% - 99% typical

Night Consumption: 7 mA 6 mA 6 mA 5 mA

Battery type: 4S LiFePO48S LiFePO410S Li-ion 12S LiFePO412S Li-ion 13S Li-ion 16S LiFePO414S Li-ion

Charge Prole: CC/CV

CV Voltage: 14.2 V 28.4 V 41.7 V 42.6 V 50 V 54.2 V 56.8 V 58.4 V

Battery Temperature Compensation: Disabled

Maximum Recommended Panel Vmp: 13 V 26 V 39 V 39 V 41 V 43 V 43 V 43 V

Maximum Recommended Panel Power: 105 W 210 W 325 W 325 W 325 W 350 W 350 W 350 W

Electrical Eciency: 95% - 97% typical 96% - 98% typical 96% - 98% typical 96% - 98% typical 96% - 98% typical 96% - 99% typical 96% - 99% typical 96% - 99% typical

Night Consumption: 7 mA 6 mA 6 mA 6 mA 6 mA 5 mA 5 mA 5 mA

Li-14.2V-WP Li-28.4V-WP Li-56.8V-WP

Weight: 10.3 oz. , 290 g

Dimensions: 5.5 x 3.2 x 2.2” (14 x 8.1 x 5.5 cm)

Warranty: 5 years

GVB-8-WP, All Models

Li-41.7V-WP Li-54.2V-WP Li-58.4V-WP

(5) Starting from S/N 188100, the Float Voltage was reduced on Pb models. For the previous version, please refer to manual revision 6.0 | 2021.

(6) 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.

Li-42.6V-WP Li-50.0V-WP

MODEL (GVB-8-**)

This manual suits for next models

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