NOCO Genius G3500 Series User manual

NOCO~
G3500v2.5
User
Guide
~.&DANGER
PRIOR TO USE, READ AND UNDERSTAND
PRODUCT SAFETY INFORMATION.
Failure
to
follow the instructions may result
in
ELECTRICAL SHOCK, EXPLOSION,
or
FIRE,
which may result
in
SERIOUS
INJURY, DEATH, DAMAGE TO DEVICE
or
PROPERTY. Do not discard this information.
Welcome.
Thank you for buying the NOCO Genius®
G3500. Read and understand the User Guide before
operating the charger. For questions regarding our
chargers, view our comprehensive support information at
www.no.co/support.
To
contact NOCO for personalized
support (not available
in
all areas), visit www.no.co/connect.
What's In The Box.
• G3500 Smart Charger
•
(1)
Battery Clamp Connectors
w/lntegrated Eyelet Terminal Connectors
• User Guide
• Information Guide and Warranty

Contacting NOCO.
Website: no.co
Email: [email protected]
Mailing Address: 30339 Diamond Parkway,
#1
02
Glenwillow, OH
44~39
United States
of
America
About
G3500.The
NOCO Genius® G3500 represents
some
of
the most innovative and advanced technology
on
the market, making each charge simple and
easy.
It is
quite possibly the safest and
most
efficient charger you will
ever use. The G3500 is designed for charging
all
types
of
12V lead-acid and 12Vlithium-ion batteries, including Wet
(Flooded), Gel, MF (Maintenance-Free),
CA
(Calcium), EFB
(Enhanced Flooded Battery), AGM (Absorption Glass Mat),
and LIB (Lithium lon) batteries. It is suitable for charging
battery capacities
up
to
120 Amp-Hours and maintaining
all
battery sizes.
Getting Started. Before using the charger, carefully
read the battery manufacturer's specific precautions and
recommended rates
of
charge for the battery. Make sure
to
determine the voltage and chemistry
of
the battery by
referring
to
your battery owner's manual prior
to
charging.
Mounting.
The G3500 has four
(4)
external holes for
mounting. Mount the charger in a desired location with
#6 self-drill screws. Make sure there are
no
obstructions
behind the mounting surface. It is important
to
keep in mind
the distance
to
the battery. The DC cable length from the
charger, with either the battery clamp
or
eyelet terminal
connectors,
is
approximately 75-inches
(1
,900mm). Allow
for 12-inches (304mm)
of
slack between connections.
Charging Modes. The G3500 has eight
(8)
modes:
Standby, 12V NORM, 12VCOLD/AGM, 12V NORM [Small],
12V COLD/AGM [Small], 6V NORM, 12V LITHIUM, and 12V
REPAIR.
Some charge modes must be pressed and held
for three
(3)
seconds
to
enter the mode. These "Press and
Hold" modes are advanced charging modes that require
yourfull attention before selecting. "Press and Hold" are

indicated on the charger by a red line. It is important
to understand the differences and purpose of each
charge mode. Do not operate the charger until you
confirm the appropriate charge
mode for your battery.
Below is a brief description:
Mode
Standby
12V
NORM
12V
COLD/
AGM
12V
NORM
[Small]
12V
COLD/
AGM
[Small]
Explanation
In Standby mode, the charger is not
charging
or providing any power to
the battery. Energy Save is activated
during this mode, drawing microscopic
power from the electrical outlet. When
selected, an orange
LED will illuminate.
For charging 12-vott Wet Cell, Gel Cell,
Enhanced Flooded, Maintenance-Free
and Calcium batteries. When selected,
a white LED will illuminate.
For charging 12-vott batteries
in cold
temperatures below 50°F
(1 0°C) or
AGM batteries. When selected, a blue
LED
witt illuminate.
For charging 12-volt Wet Cell, Gel Cell,
Enhanced Flooded, Maintenance-Free
and Calcium batteries. When selected,
a white LED will illuminate.
For charging 12-volt batteries
in cold
temperatures below 50°F
(1 0°C) or
AGM batteries. When selected, a blue
LED will illuminate.
2

Mode
6V
NORM
Press & Hold
12V
LITHIUM
Press &Hold
12V
REPAIR
Press &Hold
Explanation
For charging 6-volt Wet Cell, Gel Cell,
Enhanced Flooded, Maintenance-Free
and Calcium batteries. When selected, a
white LED will illuminate.
For charging
12 -volt lithium-i on batteries,
including lithium iron phosphate. When
selected, a blue LED will illuminate.
An advanced battery recovery
mode
for repairing and storing, old, idle,
damaged, stratified
or sulfated
batteries. When selected, a red LED will
illuminate and flash
Using 6V NORM. [Press & Hold]
6V NORM charge mode is designed for 6-volt lead-acid
batteries
only, like Wet Cell, Gel Cell, Enhanced Flooded,
Maintenance-Free and Calcium batteries. Consult the
battery manufacturer before using this mode.
CAUTION. THIS MODE
IS FOR 6-VOLT LEAD-ACID
BATTERIES
ONLY.
Using 12V Lithium. [Press & Hold]
12V Lithium charge mode is designed for 12-volt lithium-ion
batteries only, including lithium iron phosphate.
CAUTION. USE THIS MODE WITH CARE. THIS MODE
IS FOR 12-VOLT LITHIUM BATIERIES ONLY. LITHIUM-
ION BATTERIES ARE MADE
AND CONSTRUCTED
IN DIFFERENT WAYS AND SOME MAY OR MAY NOT
CONTAIN A BATTERY MANAGEMENT SYSTEM (BMS).
CONSULT THE LITHIUM BATTERY MANUFACTURER
BEFORE CHARGING AND
ASK FOR RECOMMENDED
CHARGING RATES AND VOLTAGES. SOME LITHIUM-ION

BATIERIES MAY BE UNSTABLE AND UNSUITABLE
FOR
CHARGING.
Using 12V Repair. [Press & Hold]
12V Repair is an advanced battery recovery mode for
repairing and storing, old, idle, damaged, stratified
or
sulfated batteries.
Not
all
batteries can be recovered.
Batteries tend
to
become damaged if kept at a low
charge and/or never given the opportunity to receive
a
full
charge. The most common battery problems
are battery sulfation and stratification. Both battery
sulfation and stratification will artificially raise the open
circuit voltage
of
the battery, causing the battery to
appear fully charged, while providing low capacity. Use
12V Repair
in
attempt
to
reverse these problems. For
optimal results, take the 12-volt battery through a full
charge cycle, bringing the battery
to
full charge, before
using this mode. 12V Repair can take
up
to
four
(4)
hours to complete the recovery process and will return
to Standby when completed.
CAUTION. USE THIS MODE WITH CARE. THIS
MODE
IS
FOR 12-VOLT LEAD-ACID BATIERIES
ONLY.
THIS MODE USES A HIGH CHARGING VOLTAGE
AND MAY CAUSE SOME WATER LOSS
IN
WET
(FLOODED) CELL BATIERIES. BE ADVISED, SOME
BATIERIES AND ELECTRONICS MAY BE SENSITIVE
TO HIGH CHARGING VOLTAGES. TO MINIMIZE RISKS
TO ELECTRONICS, DISCONNECT THE BATIERY
BEFORE USING THIS MODE.
Connecting
to
the
Battery.
Do not connect the AC power plug until
all
other
connections are made. Identify the correct polarity
of
the battery terminals on the battery. The positive battery
terminal
is
typically marked by these letters or symbol
(POS,P,+). The negative battery terminal
is
typically
marked by these letters
or
symbol (NEG,N,-). Do not
make any connections to the carburetor, fuel lines,
or
thin, sheet metal parts. The below instructions are for a
negative ground system (most common). If your vehicle
is
a positive ground system (very uncommon), follow
the below instructions
in
reverse order. 4

1.) Connect the positive (red) battery clamp or eyelet
terminal connector
to the positive (POS,P,+) battery
terminal.
2.) Connect the negative (black) battery clamp or eyelet
terminal connector to the negative (NEG,N,-) battery
terminal
or vehicle chassis.
3.) Connect the battery charger's
AC power plug into a
suitable electrical outlet. Do not face
the battery when
making this connection.
4.) When disconnecting the battery charger, disconnect
in the reverse sequence, removing the negative first (or
positive first for positive ground systems).
Begin Charging.
1.) Verify the voltage and chemistry of the battery.
2.) Confirm that you have connected the battery clamps
or
eyelet te rminal connectors properly and the AC power plug
is plugged into an electrical outlet.
3.) The charger will begin
in Standby mode, indicated by
an orange LED.
In Standby, the charger is not providing
any power.
4.) Press the
mode button to toggle to the appropriate
charge
mode (press and hold for three seconds to enter an
advanced charge mode) for the voltage and chemistry
of
your battery.
5.) The
mode LED will illuminate the selected charge mode
and the Charge LEOs will illuminate (depending on the
health
of the battery) indicating the charging process has
started.
6.) The charger can
now be left connected to the battery at
all times to provide maintenance charging.

Understanding Charge LEOs.
The charger has four (4) Charge LEDs -25%, 50%,
75% and 100%. These Charge LEOs indicate the
connected battery(s) state-of-charge (SOC). See the
explanation below:
LED
25%
Red LED
25% 50% 75% 100%
eooO
50%
Red LED
25%50%75% 100%
eeoO
75o/o
Orange LED
25%50%75% 100%
eeeO
100%
Green LED
25%50%75%100%
oooe
Maintenance
Green
LED
25% 50% 75% 100%
oooe
Explanation
The 25% Charge LED will slowly
pulse "on" and "off", when the battery
is less than 25o/o fully charged. When
the battery is 25% charged, the red
Charge LED will be solid.
The
50% Charge LED will slowly
pulse "on" and "off", when the battery
is less than 50% fully charged. When
the battery is 50% charged, the red
Charge LED will be solid.
The 75% Charge LED will slowly
pulse "on" and "off", when the battery
is less than 75% fully charged. When
the battery
is 75o/o charged, the
orange Charge LED will
be solid.
The 1
00% Charge LED will slowly
pulse "on" and "off", when the battery
is less than 100% fully charged. When
the battery is fully charged, the green
LED will
be solid, and the 25%, 50%
and 75% Charge LEOs will turn "off".
During maintenance charging, the
100% Charge LED will pulse "on"
and
11
0ff'' slowly. When the battery is
topped off and fully charged again,
the 1
00% Charge LED will turn
solid green. The charger can
be left
connected
to the battery indefinitely.
6

Understanding Advanced Diagnostics.
Advanced Diagnostics is used when displaying Error
Conditions. It will display a series
of blink sequences
that help you identify the cause
of the error and potential
solutions.
All Error Conditions are displayed with the Error LED
and Standby LED flashing back and forth. The number
of flashes between each pulse denotes a potential Error
Condition (except reverse polarity and low-voltage battery).
r -...
Error
Reason/So~ution
Single Battery will nothold a charge.
Flash
Have batterychecked by a
professional.
Double Possible battery short.
Flash
Have battery checked by a
professional.
Triple
Batteryvoltage is too high for
the selected charge mode.
Flash
Checkthe battery and charge
mode.
Error LED
Reverse polarity. Reverse the
Solid Red
battery connections.
Standby Batteryvoltage is
too low for
charge to detect or charger
Solid Orange is in supply. Jumpstartthe
battery
to raise the battery
voltage.
.J

•••
Memory
•••
Returns to last selected mode when restarted
•••
~
Interactive
Alters the charging process based on organic
battery feedback
Recovery
a Applies a high-voltage pulse charge when
low-voltage, sulfation
or lost capacity is
detected
Safe
• Protects against reverse polarity, sparks,
overcharging, overcurrent, open-circuits,
short-circuits and overheating
Fast
2X
Charges two times faster than traditional
battery chargers
-A.,-
Compensation
Adjusts for varying AJC line voltage for
consistent charging
~·
Rugged
Dirt, water, UV, impact and crush resistant
Compact
Iii High-frequency energy conversion for
ultra-compact, lightweight and portable
charger
CJ
Start-Stop
Counteracts increased cyclic energy demands
placed on batteries in micro-hybrid vehicles
" Firewall
Multi-level safety barrier that prevents
abnormal and unsafe conditions 8

....
1
Optimization
Stabilizes internal battery chemistry for
increased performance and longevity
Maintenance
Plus
Keeps the battery fully charged without
overcharging allowing the charger
to
be
safely
connected indefinitely
Energy
Save
Minimizes energy consumption when full
power is not needed
Load
Tracking
Charge LEOs dynamically trackthe
batteries state-of-charge when a load
outpaces the charge current
Diagnostics
Intuitive visual diagnostic tool for detecting
reverse polarity, low-voltage
or
damaged
batteries
CAN
BUS
Automatically enables the charging port
to
charge CANBUS systems
Thermal Monitor
Internal temperature sensors adjust charge
based on ambient climate

Charging Steps.
A0 0 ~ . A0 ~ ~ ~ r{Q
~v oC3 ~e; .(ltv <Qv ~0 ~0 ~v
~'li ~ _rP ·~ ~Q · ~q; r:-'li
~ A~ /l..r.o- '\.~ s0 ·~ . ~e;
V "C 'f> Q~ ~~·
Step 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 agentle (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, efficient 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 profiles to fully recapture capacity
and optimize the specific 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.
10

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 indefinitely to keep
the battery at full charge. The battery charger can
be safely
left connected indefinitely without the risk ofovercharging.
Charging Times.
The estimated time to charge a battery is shown below. The
size
of the battery (Ah) and its depth of discharge (DOD)
greatly affect its charging time. The charge time is based
on
an average depth of discharge to a fully charged battery and
is for reference purposes only. Actual data may differ due to
battery conditions. The time to charge a normally discharged
battery is based on a 50% DOD.
Battery Size Approx.Time
to Charge In Hours
Ah 6V 12V
20 2.9 2.9
40 5.7 5.7
80 11.4 11.4
100 14.3 14.3
120 17.1 17.1

Technical Specifications.
InputVoltage AC: 100-240 VAC, 50-60Hz
Working Voltage AC: 100-240
VAC, 50-60Hz
Efficiency: 85% Approx.
Power: 60W Max
Charging Voltage: Various
Charging Current:
3. 5A (12V & 6V),
.9A {12V Small)
Low-Voltage Detection: 2V (12V), 2V
(6V)
BackCurrent Drain: <5mA
Ambient Temperature:
ooc to +40°C
ChargerType: 8 Step, Smart Charger
Type of Batteries: 6V & 12V
Battery Chemistries: Wet. Gel,
MF, CA, EFB,
AGM &LIB
Battery Capacity:
Up to 120Ah (6V & 12\f),
Maintains All Battery Sizes
Housing Protection: IP65
Cooling: Natural Convection
Dimensions
(L xW x H): 7.6 x 2.7 x 1.9 Inches
Weight: 1.13 Pounds
12

•
[email protected]
30339
Diamond Parkway,
#1
02
Glenwillow, OH 44139
United States
of
America
no.co
NPD111
020160

NOCO~
Important Product Information
Guide and Limited Warranty
.& DANGER
READ AND UNDERSTAND ALL SAFETY
~
INFORMATIOIN BEFORE USING THIS
PRODUCT. Failure
to follow these safety
instructions may result in ELECTRICAL
SHOCK, EXPLOSION,
FIRE which may
result in a SERIOUS INJURY, DEATH, or
PROPERTY DAMAGE.
1ft
Electrical Shock. Charger is an electrical
device that can
shock and cause serious
injury.
Do not cut power cords. Do not
submerge
in water or get wet.
Explosion. Unmonitored, incompatible, or
.£. damaged batteries can explode if used with
charger.
Do not leave charger unattended
while
in use. Do not attempt to charge a
damaged
or frozen battery. Use charger
only with batteries
of recommended voltage.
Operate charger in well ventilated areas.
~
Fire. Charger is an electrical device that
emits heat and is capable
of causing burns.
Do not cover charger. Do
not smoke or use
any source
of electrical spark or fire when
operating charger. Keep charger away from
combustible materials.
..,J

~DANGER
Eye Injury. Wear eye protection when
operating charger. Batteries can explode
and cause flying debris. Battery acid can
cause eye and skin irritation.
In the case of
contamination of eyes or skin, flush affected
area with running clean water and contact
poison control immediately.
Explosive Gases. Working in the vicinity
of a lead-acid or lithium-ion battery is
dangerous. Batteries generate explosive
gases during normal battery operation.
To
reduce risk of battery explosion, follow all
safety information instructions and those
published
by the battery manufacturerand
manufacturer
of any equipment intended
to be used in the vicinity of battery. Review
cautionary markings
on these products and
on engine.
Important Safety Warnings
Proposition 65. Battery posts, tenninals, and related
accessories contain chemicals, including lead. These
materials are known
to the State of California to cause
cancerand birth defects and other reproductive harm.
Personal Precaution. Only usecharger as intended.
Someone should be within range
of your voice or close
enough
to come to youraid in case of emergency. Have
a supply
of clean water and soap nearby in the case of
battery acid contamination. Wear complete eye protection
and protective clothing while working near a battery.
AJways
wash hands after handling batteries and related materials.
Do not handle
or wear any metal objects when working
with batteries including; tools, watches
or jewelry. If metal is
dropped onto battery, it may spark
or create a short circuit
resulting in electrical shock, fire, explosi
on which may result
in
injury, death or property damage.

Minors.
Ifthe charger
is
intended
by
"Purchaser"
to
be used
by
a minor, purchasing adult agrees
to
provide
detailed instructions and warnings
to
any minor prior
to
use. Failure
to
do
so is the sole responsibility
of
the
"Purchaser," who agrees
to
indemnify NOCO for any
unintended use
or
misuse by a minor.
Choking Hazard.
Accessories may present
a choking hazard
to
children. Do not leave children
unattended with charger or any accessory. The charger
is not a toy.
Handling.
Handle charger with care. The charger
can become damaged if impacted. Do not use a
damaged charger, including,
but
not limited to, cracks
to
the casing
or
damaged cables. Do not use charger
with a damaged powercord
or
with loose electrical
outlets. Humidity and liqui
ds
may damage charger. Do
not handle charger
or
any electrical components near
any liquid. Store and operate charger
in
dry locations.
Do not operate charger if it becomes wet. If charger is
already operating and becomes
wet
disconnect it from
the electrical outlet and battery and discontinue use
immediately. Do not disconnect the charger from an
. electrical outlet by pulling on theAC cable.
Modifications.
Do not attempt
to
alter, modify
or
repair any part
of
the charger. Disassembling charger
may cause injury, death or damage
to
property. If
charger becomes damaged, malfunctions
or
comes in
contact with any liquid, discontinue use, and contact
NOCO. Any modifications
to
the charger will void your
warranty.
Accessories.
This charger is only approved for
use with NOCO accessories. NOCO is not responsible
for usersafety
or
damagewhen using accessories not
approved
by
NOCO.
2

Extension Cords. Using an improper extension co rd
could result in
fi re and elect ri cal shock wh ich may result in
in
jury, death or damage to device and property. If extension
cord must be used, make s
ur e that: (1) The pins on the
ex tension cord plug have the same nu mbe r, size, and shape
as those of the AC
pow er co r ,j pl ug on the charger; (2) The
extension cord is properly wired and is in good
co ndition; (3)
The wi re size is as speci fi ed in T ab le 1 below.
Recommended Mi nimum AWG Size For
Extension Cords For Battery Chargers
AC Input Rating, AWG Size
of Cord
Ampe res*
Equal To
But L ess
Le n gt h Of Cord, Feet (m)
Or Greater
Than 25
50 100 150
Than
{7. 6)
(15.2) (30.5) (45.6)
0 2 18 18 18 16
2 3
18 18 16
14
3 4 18 18 16 14
4 5 18 18 14 12
5 6 18 16 14
12
6 8 18 16
12 10
8 10 18
14 12 10
10 12 16 14 10 8
12 14 16 12 10 8
14 16 16 12 10 8
16 18
14 12 8 8
18 20 14
12
8 6
·1f the input rating of a charger is given in watts rather
than amperes. the corresponding ampere rati
ng is to
be determined by dividing the wattage rating by the
voltage rating -for e
xamp le:
1250W+125V= 10Ampe~s

Location. Locate the charger as far away from the
battery as possible. Do
not place the charger directly
abovethe battery as gases from battery will corrode
and damage charger. Prevent battery acid from coming
in contact with the charger. Do not operate the charger
in a closed-in area
or an area with restricted ventilation.
Do not set a battery on top of charger. Position cable
leads to avoid accidental damage by moving vehicle
parts (including hoods and doors), moving engine parts
(including
fan blades, belts, and pulleys), or what could
become a hazard that may cause injury
or death.
Operating Temperature. The charger is
designed to work in ambient temperatures between
32° and 104
o F (0° and 40° C) and stored in
temperatures between
oo and 130° F (-17° and 54° C).
Do not store or operate outside of these temperature
ranges. Do not charge a frozen battery. Discontinue
use
of charger immediately ifthe battery becomes
excessively warm.
Storage. Do not use or store your charger in areas
with high concentrations
of dust or airborne materials.
Store your charger
on flat; secure surfaces so it's not
prone to falling. Store yourcharger in a dry location.
Compatibility. The charger is only compatible
with lead-acid and lithium-ion batteries (excluding
model G750, which is for lead-acid batteries only).
Do not attempt
to use charger with any other type
of battery. Charging other battery chemistries may
result
in injury, death or property damage. Contact the
battery manufacturer prior to attempting to charge the
battery. Do not charge a battery if you are unsure
of
the battery's specific chemistry or voltage. The charger
features specialized charge modes for charging
specialized batteries. Failure
to understand the
operation
of the charging modes may result in injury,
death or property damage.
4

Lithium Charging.
Misusing a lithium-ion battery may
cause the battery
to
get
hot, rupture, or ignite, causing
serious injury, death
or
property damage.
Not
all
lithium-
ion batteries are the same chemistry
or
contain battery
management systems. Contact the lithium-ion battery
manufacturer before attempting
to
charge. The "Purchaser"
assumes
all
risks associated with lithium-ion batteries.
Cleaning.
Unplug the charger before attempting any
maintenance
or
cleaning. Clean and drycharger immediately
if it comes in contact with liquid
or
any type
of
contaminant.
Before cleaning, disconnect charger from electrical outlet and
battery. Use a soft, lint-free (microfiber) cloth. Avoid getting
moisture in openings.
Explosive Atmospheres.
Obey all signs and
instructions.
Do
not operate charger in any area with a
potentially explosive atmosphere, including fueling areas
or
areas which contain chemicals
or
particles such as grain, dust
or metal powders.
High-Consequence Activities.
This device is
not
intended for use where the failure
of
the device could lead
to
injury,
death
or
severe environmental damage.
Radio Frequency Interference.
Charger is
designed, tested, and manufactured
to
comply with
regulations governing radio frequency emissions. Such
emissions from the charger can negatively affect the operation
of other electronic equipment, causing them
to
malfunction.
NOCO
Genius Battery Charger Five (5) Year
Limited Warranty.
The NOCO Company ("NOCO") warrants that its products
(the "Product") will be free from defects in material and
workmanship for a period
of
five
(5)
years from the date
of
purchase (the "Warranty Period"). For defects reported during
the Warranty Period, NOCO will, at its discretion, and subject
to
NOCO's technical support analysis, either repair
or
replace,
for the fees set forth below. Replacement parts and products
will be
new
or serviceably used, comparable
in
function
and performance
to
the original part and warranted for the
remainder
of
the original Warranty Period.