GENASUN GV-4 Solar Charge Controller Instruction Manual

ENASUN GV-4 Solar Charge Controller

For models

• GV-4-Pb-12V: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded
• GV-4P-Pb-12V: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded
• GV-4-Pb-CV : 12 V Custom Multi-Stage Lead-Acid/AGM/Gel/ Sealed/Flooded

Safety Instructions

This manual contains important instructions for the GV-4-Pb-12V, GV-4P-Pb-12V, and GV-4-Pb-CV solar charge controller that shall be followed during installation and maintenance. Various models of the GV-4 are available as follows:

• GV-4-Pb-12V: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded
• GV-4P-Pb-12V: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded
• GV-4-Pb-CV : 12 V Custom Multi-Stage Lead-Acid/AGM/Gel/Sealed/Flooded
• GV-4-Pb-PCB : 12 V Multi-Stage Lead-Acid/AGM/Gel/Sealed/Flooded

The GV-4 is intended for charging 12 V Lead-Acid, AGM, Gel, Sealed, and Flooded batteries. Consult your battery charging specifications to ensure that the GV-4 is compatible with your chosen batteries.
The GV-4 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: 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-4-Pb-12V and GV-4-Pb-CV.

To avoid stress on the GV-4 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. Use only 12 – 30 AWG (3.0 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: 3 – 5 in-lbs, 0.35 – 0.55 Nm.

Grounding is not necessary for operation and is at the user’s discretion. If the GV-4 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.

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.

Product Certifications

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.

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 (use within 1 ft (0.3 m) of batteries. See Caution, p.2).
• The GV-4 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.
• Do not mount in direct sunlight or near a source of heat.
• Allow adequate airflow around the controller.
• For outdoor use, the controller must be housed in an enclosure providing protection at least equivalent to NEMA Type 3.

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.

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-4.
• Never connect the panel negative to the battery negative, as your batteries may be damaged.
• Do not use blocking diodes for single-panel installations. The GV-4 prevents reversecurrent 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 GV-4 at the coldest possible expected temperature

Note: In the GV-4, the positive side of the battery is connected internally to the positive 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 GV-4 does not provide protection against over-discharge.

CAUTION, RISK OF FIRE OR EXPLOSION: Do not make the final battery connection near leadacid batteries that have recently been charging

Status Indication

The GV-4 has a MULTICOLOR LED.

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 0.15 A):

4 – 5 SEC. BETWEEN GREEN BLINKS

Charging (between 0.15 – 1.5 A):

FAST GREEN BLINKS

Charging (high current, more than 1.5 A):

LONGER, SLOWER GREEN BLINKS

Charging at the current limit:

The GV-4 is overloaded and limiting the charging current.
LONG, THEN SHORT GREEN BLINKS

Battery charged : The battery is in the absorption or float charging stage.

SOLID GREEN LED

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 due to low battery voltage. If the nominal battery voltage is correct (12 V), charge the battery by some other means before use.

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

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-4 battery terminal screws.
• Check the GV-4 terminal area for water or mechanical damage.

The GV-4 will not operate without a battery. If the system appears to be overcharging or the GV-4 will not begin charging, ensure that the solar panel is wired only to the GV-4, and in particular that the solar panel negative terminal is not connected to ground (battery negative). If the GV-4 does not appear to be charging, note that the GV-4 waits up to one minute before trying to restart if is has shut down due to lack of power from the solar panel. For more in-depth system troubleshooting, please visit the support area of our website: https://sunforgellc.com/learning-center/

Specifications

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

(3) Max current that the controller could draw from an unlimited source. This specification is not intended for determining PV input.

• (4) 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.
• (5) Max ambient temperature for full operating power. Test conditions: 16 V input, 13 V output, GV-4 vertically (wall) mounted.
• (6) This specification does not apply to the GV-4-PCB. The GV-4-PCB specifications are as follows: Weight: 1.02 oz (29 g); Dimensions: 3.3″ x 1.9″ x 0.9″ (8.3 cm x 4.8 cm x 2.3 cm); Environmental Protection: IP00.

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.

SUNFORGE LLC

• 2598 FORTUNE WAY SUITE K VISTA, CA 92081 USA
•    https://sunforgellc.com

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