GENASUN GV-10-Pb-12V Solar Charge Controllers Instruction Manual

: June 1, 2024
: GENASUN

Table of Contents

GENASUN GV-10-Pb-12V Solar Charge Controllers
Safety Instructions
Inspection & Maintenance
Product Certifications1
Installation & System Connections
MOUNTING
Status Indication
Troubleshooting
Specifications
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Download This Manual (PDF format)

GENASUN GV-10-Pb-12V Solar Charge Controllers

GV-10 Manual
Solar Charge Controllers with Maximum Power Point Tracking

For models:

GV-10-Pb-12V: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded
GV-10-Pb-CV: 12 V Custom Multi-Stage Lead-Acid/AGM/Gel/Sealed/Flooded
GV-10-Li-12.5V: 11.1 V (3S) Lithium Cobalt/Manganese/Nickel
GV-10-Li-14.2V: 12 V (4S) Lithium Iron Phosphate
GV-10-Li-16.7V: 14.8 V (4S) Lithium Cobalt/Manganese/Nickel
GV-10-Li-CV: Custom CC/CV or Multi-Stage Lithium

10.5 A / 140 W

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

Safety Instructions

This manual contains important instructions for the GV-10-Pb and GV-10-Li solar charge controllers that shall be followed during installation and maintenance. Various models of the GV-10 are available to charge different battery types as follows:

GV-10-Pb-12V: 12 V Lead-Acid/AGM/Gel/Sealed/Flooded
GV-10-Pb-CV: 12 V Custom Multi-Stage Lead-Acid/AGM/Gel/Sealed/Flooded
GV-10-Li-12.5V: 11.1 V (3S) Lithium Cobalt/Manganese/Nickel
GV-10-Li-14.2V: 12 V (4S) Lithium Iron Phosphate
GV-10-Li-16.7V: 14.8 V (4S) Lithium Cobalt/Manganese/Nickel
GV-10-Li-CV: Custom CC/CV or Multi-Stage Lithium
GV-10-Li-PCB CC/CV or Multi-Stage Lithium
GV-10-Pb-PCB 12 V Multi-Stage Lead-Acid/AGM/Gel/Sealed/Flooded

Consult your battery charging specifications to ensure that the GV-10 is compatible with your chosen batteries.
The GV-10 includes a 20 A fast-acting ATO fuse rated 32 V.
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 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. ATTENTION: REMPLACER SEULEMENT AVEC LE MÊME TYPE ET VALEUR NOMINALE DE FUSIBLE. DÉBRANCHER TOUTES LES SOURCES D’ALIMENTATION AVANT L’ENTRETIEN. PAS ISOLÉ.
CAUTION for the GV-10-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-10-Pb-12V and GV-10 -Pb-CV.
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 GV-10 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.

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. 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.

Inspection & Maintenance

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.
Inspect the controller at least once per year to ensure proper performance.

Product Certifications1

$GENASUN-GV-10-Pb-12V-Solar-Charge-Controllers-FIG- $1$$

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.

SELECTING THE BATTERY TYPE (LEAD-ACID / PB MODEL ONLY)

Your GV-10-Pb-12V controller is supplied set to the “SEALED” charging profile, which is appropriate for most types of sealed lead-acid and gel batteries, as well as some types of AGM batteries. A “FLOODED” setting is available for flooded batteries and other types of AGM batteries. The “FLOODED” setting includes equalization charging. Please consult the specification table at the end of this manual to determine the best setting for your battery type. To change your GV-10 controller to the “FLOODED” setting, unscrew the four screws on the bottom of the controller, remove the top, and install the supplied jumper on the 6-pin connector as shown in diagram 1. Use care when installing the jumper, as incorrect installation can damage the controller. For sealed batteries, do not install the jumper.

$GENASUN-GV-10-Pb-12V-Solar-Charge-Controllers-FIG- $2$$

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 GV-10 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 20 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. While connecting the battery first will not damage the GV-10, we recommend connecting the panel first. This eliminates the risk of short-circuiting the panel while the GV-10 is operating, which can cause damage.

In most applications, the panel should be connected only to the GV-10.
Do not use blocking diodes for single-panel installations. The GV-10 prevents reversecurrent flow.
Multiple panels may be connected in parallel up to the maximum power limit of the controller, with a blocking diode used for each panel (unless otherwise recommended by the panel manufacturer). These panels should be the same model and facing the same direction, otherwise we recommend using a separate controller for each panel.
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-10 at the coldest possible expected temperature.

Note: In the GV-10, the negative side of the battery is connected internally to the negative side of the solar panel.

$GENASUN-GV-10-Pb-12V-Solar-Charge-Controllers-FIG- $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 GV-10 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.

Note: Voltages above 25 V applied to the battery terminals will immediately destroy the GV-10. We recommend wiring the controller directly to the battery through its own circuit, and not through any battery switch or selector. Do not share wiring between the GV-10 and an alternator

Status Indication

The GV-10 has a MULTICOLOR LED.

LED RUN/CHARGE INDICATION
Standby: The battery is connected properly and ready to charge when solar panel power is available.

LED ERROR INDICATION
Over-temperature: The controller’s internal temperature is too high.

$GENASUN-GV-10-Pb-12V-Solar-Charge-Controllers-FIG- $5$$

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-10 battery terminal screw.
Check the GV-10 terminal area for water or mechanical damage.
Check the 20 A fuse inside the GV-10.

The GV-10 will not operate without a battery. If the system appears to be overcharging or the GV-10 will not begin charging, ensure that the solar panel is wired only to the GV-10. If the GV-10 does not appear to be charging, note that the GV-10 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 GV-10 by removing the four screws on the bottom of the enclosure. If the fuse is blown, replace it with a 20 A fast-acting ATO or ATC fuse rated 32 V or higher. For more in-depth system troubleshooting, please visit the support area of our website: https://sunforgellc.com/learning-center/

Specifications

Max Recommended Panel Power:| GV-10-Pb-12V

140 W

| GV-10-Li-12.5V

120 W

| GV-10-Li-14.2V

140 W

| GV-10-Li-16.7V

160 W

| GV-10-Li-CV

(See specs for closest CC/CV voltage.)

---|---|---|---|---|---
Max Input Voltage:| | | 34 V| |
Recommended Max Panel Voc at STC:| | | 27 V| |
Max Input Short Circuit Current:2| | | 10.5 A| |
Max Input Current:3| | | 19 A| |
Nominal Battery Voltage:| | | 12 V| |
Min Battery Voltage for Operation:| | | 8.5 V| |
Rated Charging Current:| | | 10.5 A| |
Input Voltage Range:| | | 0 – 34 V| |
Operating Temperature:| | | -40 °C – 85 °C| |
Max Full Power Operating Ambient:4| | | 70 °C| |
Charge Profile:| Multi-Stage with Temperature Compensation| | CC/CV| | CC/CV or Multi-Stage
---|---|---|---|---|---
Battery type:| Lead-Acid FLOODED (jumper in place)| Lead-Acid SEALED (no jumper)| 3S Li-ion| 4S LiFePO4| 4S Li-ion| Lithium
Equalization Voltage:| 15.0 V| –| | –| |
Equalization Time:| 2 Hours| –| | –| |
Equalization Interval:| 30 Days| –| | –| |
Bulk Voltage:| 14.6 V| 14.3 V| | –| |
Absorption Voltage:| 14.4 V| 14.1 V| | –| |
Absorption Time:| 2.5 Hours| | –| |
Float Voltage (Pb models) or CV Voltage (Li models):|

13.5 V

|

13.7 V

|

12.5 V

|

14.2 V

|

16.7 V

|

Custom Voltage

Panel Isc. Max input power and max input voltage requirements must also be respected.
Max current that the controller could draw from an unlimited source. This specification is not intended for determining PV input.
Max ambient temperature for full operating power.
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.
This specification does not apply to the GV-10-PCB. Specifications for the GV-10-PCB are as follows: Weight: 3.4 oz (96 g); Dimensions: 4.8″ x 2.2″ x 1.0” (12 cm x 5.5 cm x 2.5 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.