Genius GEN4 - Battery charger NOCO - Free user manual and instructions

USER MANUAL Genius GEN4 NOCO

• GEN Series On-Board Battery Charger

ELECTRICAL SHOCK, EXPLOSION, FIRE, AND EYE

[e-mail] 30339 Diamond Parkway, #102 Glenwillow, OH 44139 United States of America Phone: Email: Mailing Address: DANGER Before use, READ AND UNDERSTAND Quick Start Guide and Owner’s Manual and User Guide. Failure to read and understand this information could result in SERIOUS INJURY or DEATH. DO NOT REMOVE OR COVER THIS INFORMATION.2

BATTERY POSTS, TERMINALS, AND RELATED

ACCESSORIES CONTAIN CHEMICALS, INCLUDING

LEAD, KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. ALWAYS WASH YOUR HANDS AFTER HANDLING THESE PRODUCTS. DANGER WARNING FIRE HAZARD

WORKING IN VICINITY OF A LEAD-ACID

REASON, IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE CHARGER. To reduce risk of battery explosion, follow these instructions and those published by battery manufacturer and manufacturer of any equipment intended to be used in vicinity of battery. Review cautionary markings on these products and on engine. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of re, electric shock, or injury to persons. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when disconnecting charger. Do not operate charger with damaged cord or plug – replace the cord or plug immediately. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualied service facility.4 DO NOT USE EXTENSION CORDS unless absolutely necessary. Using an improper extension cord could result in a risk of re and electric shock and may result in property damage, personal injury or death. If extension cord must be used, make sure that: 1.) The pins on the extension cord plug have the same number, size, and shape as those of the AC power cord plug on the charger. 2.) The extension cord is properly wired and is in good electrical condition. 3.) The wire size is as specied in Table 1 below:

Length Of Cord, Feet (f) *If the input rating of a charger is given in watts rather than amperes, the corresponding ampere rating is to be determined by dividing the wattage rating by the voltage rating - for example: 1250 watts/125 volts = 10 amperes Do not disassemble charger; take it to a qualied service facility when service or repair is required. Incorrect reassembly may result in a risk of electric shock or re. To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

• Someone should be within range of your voice or close enough to come to your aid if you have an accident.

• Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

• Wear complete eye protection and protective clothing. Avoid touching your eyes while working near a battery. If battery acid contacts your skin or clothing, wash immediately with soap and water. If acid enters an eye, immediately ood the eye with running cold water for at least ten (10) minutes and seek medical attention as soon as possible.

• Be extra cautious when handling metal tools around a battery. If you drop a metal tool near a battery it might spark or create a short circuit between the battery terminals and some other metal part. Either event may cause a dangerous electrical shock hazard, a re, or even an explosion, resulting in property damage, personal injury, or death.

• Never smoke or allow an open spark or ame in the vicinity of the battery or engine.

• Remove all personal items made of metal, such as, rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead- acid battery can produce a short-circuited current high enough to weld a metal ring or other piece of jewelry, causing a severe burn.

• To avoid an electric arc (or spark), turn off or disconnect all of the accessories in the boat or vehicle. Always remove the cable that is connected to grounded terminal from battery rst.

• Make sure the area around the battery is well-ventilated while the battery is being charged. If necessary, use a non-metallic material to fan away the gas in the area.

• If necessary, clean the battery terminals. Be careful to keep the corrosion and other debris from coming in contact with your skin or eyes.

• If the battery is not a sealed battery, add distilled water to each cell (if necessary) until the battery acid solution reaches the level specied by battery manufacturer. Do not overll. For a battery without cell caps, such as a valve regulated lead-acid battery (VRLA), carefully follow the battery manufacturer’s charging instructions.

• Before charging, carefully read the battery manufacturer’s specic precautions and recommended rates of charge.

• Determine the voltage of the battery by referring to the boat’s or vehicle’s owner’s manual and make sure that the battery charger has6 compatible voltages.

• If using an extension cord, always connect to the battery charger rst, before connecting to an electrical outlet. When disconnecting, always disconnect from the electrical outlet rst. Make sure the electrical outlet is a 120VAC GFCI (Ground Fault Circuit Interrupt) outlet.

LOCATING BATTERY CHARGER

• Locate the battery charger as far away from the battery as possible.

• Never place the battery charger directly above the battery; gases from battery will corrode and damage battery charger.

• When reading electrolyte specic gravity or ling battery, never allow battery acid to come in contact with the battery charger.

• Do not operate the battery charger in a closed-in area or an area with restricted ventilation.

• Do not set a battery on top of battery charger. BATTERY SPECS The following recommendations should ONLY be considered as guidelines. Always refer to the battery manufacturer’s recommendations for battery charging. The GEN Series On-Board Battery Chargers are suitable for charging all types of 12V lead-acid batteries, including Wet (Flooded), Gel, MF (Maintenance-Free) and AGM (Absorption Glass Mat) batteries. The GEN Series On-Board Battery Chargers can be used on battery sizes from 25 to 230Ah, but can also maintain all battery sizes.CONNECTING TO THE BATTERY Before you connect to the battery(s), make sure that the AC power plug is not connected to an electrical outlet. DO NOT CONNECT THE BATTERY CHARGER AC POWER PLUG TO THE ELECTRICAL OUTLET UNTIL ALL OTHER CONNECTIONS ARE MADE. Make sure you have identied the correct polarity of the battery terminals on the battery(s). The POSITIVE battery terminal is typically marked by these letters or symbols (POS,P,+). The NEGATIVE battery terminal is typically marked by these letters or symbols (NEG,N,-). If you are having difculty determining the polarity of the battery terminals, contact the battery manufacturer before proceeding. 1.) Conrm that you have a 12V battery(s). This battery charger is for 12V LEAD-ACID BATTERIES ONLY. 2.) Connect the POSITIVE (Red) eyelet terminal connector to the POSITIVE (POS,P,+) battery terminal. 3.) Connect the NEGATIVE (Black) eyelet terminal connector to the NEGATIVE (NEG,N,-) battery terminal. 4.) Repeat steps 2 and 3 for each battery bank. 5.) When disconnecting the battery charger, disconnect in the reverse sequence, removing the NEGATIVE rst.

HOW TO START CHARGING

1.) Conrm that you have connected the eyelet terminal connectors properly. 2.) Connect the battery charger’s AC power plug into a suitable electrical outlet. DO NOT FACE THE BATTERY WHEN MAKING THIS CONNECTION. 3.) Charge battery(s) until fully charged. A Green LED will illuminate solid when the battery is fully charged. 4.) The battery charger can be left connected to the battery at all times to provide maintenance charging. However, it is good practice to check the battery periodically. CHARGER MAINTENANCE GEN Series On-Board Battery Chargers do not require any maintenance. Do not attempt to open or repair the battery charger as it will invalidate the limited warranty. A damp cloth may be used to clean dust, dirt, or other debris off of the battery charger. BEFORE ATTEMPTING TO CLEAN THE BATTERY CHARGER, MAKE SURE YOU REMOVE THE AC POWER PLUG FROM THE POWER SOURCE.8

UNDERSTANDING LED LIGHTS

Each battery bank contains two (2) LEDs - a CHARGE LED and an ERROR LED. The CHARGE LED indicates the charging process (Red when charging, Green when charged) and the ERROR LED displays a Reverse Polarity or Error Condition. To understand the LED Light conguration better, see the chart below: When Charging RED When Charged GREEN Reverse Polarity ORANGE

LED LIGHTS EXPLANATION

When the battery is charging, the CHARGE LED will be illuminated RED. The CHARGE LED will remain a solid RED color (not blinking) until the battery is fully charged. When the battery is fully charged, the CHARGE LED will be illuminated GREEN. The CHARGE LED will remain a solid GREEN color (not blinking) until either the battery charger is disconnected or the battery becomes discharged. If a Reverse Polarity condition exists, the ORANGE ERROR LED will illuminate. This ERROR condition will be displayed whether the charger is plugged in or disconnected from an AC power source. Reverse the battery connections to x this ERROR. If an ERROR condition exists, the Charge LED(s) will ash, and/or the ERROR LED with illuminate and/or ash. There are several reasons an ERROR condition could exist. For help troubleshooting ERROR conditions, see the section entitled TROUBLESHOOTING. Error Condition FLASHINGFEATURE OVERVIEW

MULTIPLE BATTERY COMPATIBILITY

(GEN2, GEN3 & GEN4) Independently charges multiple 12V batteries WATERPROOF 100% completely sealed, protects against extreme working environments & rated at IP68 FULLY INTERACTIVE Automatically adjusts itself to changing current needs

Reverse polarity, short circuit, open circuit, spark proof, overheat, overcurrent & overcharge protected

HF/HE SWITCH MODE DESIGN

High-frequency, high-efciency for a lightweight, compact charger

RAPID CHARGING TECHNOLOGY

Charges batteries 2X faster than traditional linear battery chargers

VARIABLE INPUT COMPENSATED

100% full charge even with varying A/C input voltages RECOVERY MODE Recovers deeply discharged & sulfated batteries with pulse charging

MULTIPLE BATTERY CHEMISTRY

Safely charges Wet, Gel, MF & AGM batteries10 ABNORMALITY PROTECTION Automatically shuts “off” if charger remains in Bulk charge mode for an extended period of time

SPECIFIC GRAVITY OPTIMIZATION

A stabilizing charge that optimizes the specic gravity of a battery for increased performance IGNITION PROTECTED Non-igniting and temperature controlled for safe and worry-free operation CHARGING TIMES The time required for the GEN Series to charge a normally discharged battery is shown below. Deeply discharged batteries may take longer to charge depending on the depth of discharge (DOD). The charge time is based on an average depth of discharge to a fully charged battery. *Note: The above table is for reference purposes only. Actual data may differ due to battery conditions. The time required to charge a normally discharged battery is based on an average DOD of 50%. BATTERY SIZE (Ah)

11.5Step 1 & 2: Analyze & Diagnose Checks the battery’s initial condition, including voltage, state-of- charge and health, to determine if the battery is stable before charging. Step 3: Recovery Initializes the Recovery desulfation process (if needed) for deeply discharged or sulfated batteries by pulsing small amounts of current. Step 4: Initialize Starts the charging process with a gentle (soft) charge. Step 5: Bulk Begins the Bulk charging process based on the condition of the battery and returns 80% of the battery’s capacity. Step 6: Absorption Brings the charge level to 90% by delivering small amounts of current to provide a safe, efcient charge. This limits battery gassing and is essential to prolonging battery life. Step 7: Optimization Finalizes the charging process and brings the battery to maximum capacity. In this step, the charger utilizes multi-layered charging proles to fully recapture capacity and optimize the specic gravity of the battery for increased run time and performance. The charger will switch to Maintenance if the battery tells the charger that more current is needed. Step 8: Maintenance Continuously monitors the battery to determine when a maintenance charge should be initiated. If the battery voltage falls below its target threshold, the charger will restart the Maintenance cycle until voltage reaches its optimal state and then discontinues the charge cycle. The cycle between Optimization and Maintenance is repeated indenitely to keep the battery at full charge. The battery charger can be safely left connected indenitely without the risk of overcharging. CHARGING STEPS

Analyze Step Voltage (V)Current (A) Initialize Diagnose Bulk Optimization Recovery Absorption Maintenance Excluding Cords12 TECHNICAL SPECIFICATIONS Battery Banks Amps/Bank Total Amps Input Voltage AC Working Voltage AC Nominal Voltage Efciency Charging Voltage Back Current Drain Ripple Charger Type Type of Batteries Battery Chemistries Battery Capacity Housing Protection Cooling Output Leads (Length) AC Cord (Length) Dimensions (L x W x H) Weight GEN1

BATTERY TESTING AND DIAGNOSTICS. The battery charger will not begin delivering any current to the battery(s) until the battery charger detects a ‘stable’ battery. A ‘stable’ battery means the eyelet terminal connectors are connected to the battery with the correct polarity (POSITIVE-TO- POSITIVE, NEGATIVE-TO-NEGATIVE) and have a tight, clean connection to the battery being charged. If the battery is not stable for at least three (3) seconds, the battery charger will not begin charging the battery and the battery charger will go into an ERROR condition. If the battery is connected in reverse polarity, it is considered an ‘unstable’ battery and the ERROR LED will illuminate until the ERROR is cleared by reversing the eyelet terminal connectors. Excluding CordsTROUBLESHOOTING

WHEN FLASHING LEDS ILLUMINATE

When the battery charger detects an ERROR condition, The Charge LED(s) will ash, and/or the ERROR LED with illuminate solid. If you are seeing this ERROR condition, it could be the result of one of the following situations:

• BATTERY VOLTAGE INCOMPATIBILITY Check to make sure you have a 12V battery. This battery charger is for 12V batteries only. If you attempting to charge a battery that is other than 12V, it could cause this ERROR condition. Charge the appropriate battery to resolve this ERROR condition.

• LOW VOLTAGE BATTERY If the battery voltage is below 2.0VDC (12V), it could cause this ERROR condition. In this situation, the battery charger has determined that the battery voltage is too low to begin a normal charge cycle. To increase the battery voltage and allow the battery charger to begin charging, you will need to jump start the battery.

• ABNORMALITY PROTECTION This ERROR condition is the result of the battery charger being in the Bulk mode for more than eighty (80) hours. This ERROR condition is the result of a bad battery. To resolve this ERROR condition, take the battery to a local battery store for an evaluation.

• BLOWN FUSE IN BATTERY CONNECTOR HARNESS Check the fuse in the battery connector harness. If the fuse in the battery connector harness has blown, it could cause this ERROR condition. Replace the fuse with a 15A Automotive Blade Fuse to resolve this ERROR condition.

• CORROSION ON BATTERY TERMINALS Check the battery connections for battery corrosion. If battery corrosion is present on the battery connections, it could cause this ERROR condition. Remove the battery corrosion to resolve this ERROR condition.

• LOOSE BATTERY CONNECTIONS Check the battery connections to the battery. If the battery connections are loose, it could cause this ERROR condition. Tighten the battery connections to resolve this ERROR condition.

• SULFATED, DAMAGED, OR WEAK BATTERY If you have checked all other possible ERROR conditions and cannot clear the ERROR, it is probably the result of a sulfated, damaged, or weak battery. To properly diagnose a sulfated, damaged, or weak battery, take the battery to a local battery store for an evaluation. The battery store will advise if the battery can be charged or needs replaced.14

LOW BATTERY. If you have a severely discharged battery, a battery that is below 9.0VDC, it could be the result of a defective battery. Batteries that have been severely discharged as a result of an accidental load should respond quickly when current is applied to the battery, resulting in a sharp increase in battery voltage. WHEN NO LIGHTS COME ON WHEN THE BATTERY CHARGER IS PLUGGED INTO AN ELECTRICAL OUTLET

• WEAK AC CONNECTION Check if the AC outlet has power. If the AC outlet has no or limited power, it could cause this condition. Plug a light into the AC outlet to check if the outlet has power. If the light is extremely dim, this could be the result of limited AC power. The battery charger is designed for use at 70-130VAC. If there is no power or the power is below 70VAC, locate another AC outlet that has sufcient power to resolve this ERROR condition. BULK TIMEOUT For safety, if the charger is in bulk mode for 41hours it will automatically stop charging and all LEDs will ash. If this happens, have the battery tested as it might be defective. To restart charging, disconnect AC Power and then reconnect.

WICKED SMART FEATURE

ABNORMALITY PROTECTION. If the battery charger is in the Bulk mode for more than 80 hours, the battery charger will go into an ERROR condition. This feature prevents damage if the battery is faulty.

• GEN Series On-Board Battery Charger

SIN SUPERVISION, INCOMPATIBLE, O