MANUAL G7200 GENIUS CHARGER

Posted by Felix Wu on

If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.

Disconnect the supply before making or breaking the connections to the battery.

Only charge 6V and 12V Wet, Gel, MF and AGM batteries.

The battery terminal not connected to the chassis has to be connected first.  The other connection is to be made to the chassis, remote from the battery and fuel line.  The battery charger is then to be connected to the supply mains.

After charging, disconnect the battery charger from the supply mains.  Then remove the chassis connection and then the battery connection.

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

Children should be supervised to ensure that they do not play with the appliance.

Table 1: RECOMMENDED MINIMUM AWG SIZE FOR EXTENSION CORDS FOR THE BATTERY CHARGERS

AC INPUT RATING, AMPERES

AWG SIZE OF CORD

Equal to or Greater than

But less than

Length of Cord, feet (m)

25 (7.6)

50 (15.2)

100 (30.5)

150 (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

If the input rating of a charger is given in watts rather than amperes, the corresponding ampere rating is to be determined by diving the wattage rating by voltage rating – for example: 1250 watts/125 volts = 10 amperes

Use the following precautions when you work near lead-acid batteries:

  • 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 flood the eye with running cold water for at least ten minutes and seek medical attention as soon as possible.
  • Be extra cautious when handling metal tools around a battery if you drop 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 fire, or even an explosion, resulting in property damage, personal injury, or death.
  • Never smoke or allow an open spark or flame 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 jewellery, causing a severe burn.
  • This battery charger is for charging lead-acid batteries only. Do not use the battery charger for dry-cell batteries that are commonly used with home appliances.  These types of batteries may burst and may cause property damage, personal injury or death.
  • Never charge a frozen battery.

 

Before charging

  • To avoid an electric arc (or spark), turn off or disconnect all of the accessories in the vehicle. Always remove the cable that is connected to grounded terminal from battery first.
  • Make sure the area around the battery is well-ventilated while the battery is being charged. If necessary, use a non-metallic material to blow 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 specified by battery manufacturer. Do not overfill.  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 specific precautions and recommended rates of charge.
  • Determine the voltage of the battery by referring to the vehicles owner’s manual and make sure that the charge mode is set at the correct voltage.
  • Connect and disconnect the DC output cables only after the battery charger is placed in the STANDBY mode and the AC cord is removed from the electrical outlet. Never allow the battery clamp or eyelet terminal connectors to touch each other.

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 specific gravity or filing 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 G7200 is suitable for charging all types of 12V and 24V lead-acid batteries, including Wet (Flooded), Gel, MF (Maintenance-Free) and AGM (Absorption Glass Mat) batteries.  The G7200 can be used on battery sizes from 14 to 230Ah (12V) and 14-120Ah (24V).  The battery charger can also maintain all sizes of 12V and 24V batteries.

 

Mounting Battery charger

The G7200 has four (4) external holes in the casing of the battery charger enclosure.  These external mounting holes can be used to mount the battery charger permanently in a desired location for battery charging.  When mounting the battery charger to a fixed location, keep in mind the distance to the battery from the battery charger.  The cable length from the battery charger with either the battery clamp or eyelet terminal connectors is approximately 72” (6).  Allow for at least 12” (1’) of slack in the battery connections. Thus, we recommend not to extend the battery connections past 60” (5’).

 

Connecting to the battery

Before you connect to the battery, 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 identified 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, -).

 

IF THE BATTERY IS OUTSIDE OF THE VEHICLE

  • Connect the positive (Red) battery clamp or eyelet terminal connector to the positive (POS, P, +) battery terminal.
  • Connect the negative (black) battery clamp or eyelet terminal connector to the negative (NEG, N, -) battery terminal. If you have accidentally reversed the polarity, an ERROR LED (Orange) will illuminate.  The battery charger has an internal safety feature to protect the battery charger from damage if this situation should occur. Reverse the connections to clear the error led and proceed to the next step.
  • Connect the battery charger, disconnect in the reverse sequence, removing the negative first.
  • When disconnecting the battery charger, disconnect in the reverse sequence, removing the negative first.

 

If the battery is installed inside of the vehicle

  • Position both the AC power plug and battery clamps or eyelet terminal connectors to avoid accidental damage by moving vehicle parts (i.e. hoods, doors) or moving engine parts ( i.e. fan blades, belts, pulleys).
  • Determine the vehicle’s battery system. If the positive (POS, P, +) battery terminal is connected to the vehicle chassis, then the vehicle has a positive ground system. If the negative (NEG, N, -) battery terminal is connected to the vehicle chassis, then the vehicle has a negative system.  Negative ground systems are the most common.
  • Option A) for negative ground systems, connect the positive (Red) battery clamp or eyelet terminal connector to the positive (POS, P, +) battery terminal. Next, connector to the negative (black) battery clamp or eyelet terminal connector to the vehicle chassis.  Do not connect to the carburettor, fuel lines, or thin, sheet metal parts.  Make the connection to the engine block or a heavy gauge metal part of the frame. Option B) for positive ground systems, connect the negative (black) battery clamp eyelet terminal connector to the negative (NEG, N, -) battery terminal.  Next, connect the positive (Red) battery clamp or eyelet terminal connector to the vehicle chassis.  Do not connect to the carburettor, fuel lines, or thin, sheet metal parts.  Make the connection to the engine block or a heavy gauge metal part of the frame.
  • Connect the battery charger’s AC power plug into a suitable electrical outlet. Do not face the battery when making this connection.
  • When disconnecting the battery charger, disconnect in the reverse sequence.

 

How to start charging

  • Confirm that you have connected the battery clamp or eyelet terminal connectors properly and the AC power plug is plugged into an electrical outlet.
  • The battery charger will begin in the standby mode, indicated by a green LED. In the STANDBY mode, the battery charger is not outputting any current. By pressing the mode button, toggle to the appropriate charge mode, based on the size and chemistry of your battery, to begin the charging process.
  • Depending on the charge mode selected, an LED will illuminate the selected charge mode and the charge LEDs (25%, 50%, 75%, 100%) will begin to illuminate (depending on the health of the battery), indicating the charging process has started.
  • When the battery is fully charged, all the charges LEDs will be a solid color (Red, Yellow, Green), indicating the charge process is completed.
  • 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

The G7200 does 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 to clean off of the battery charger.  Before attempting to clean the battery charger, make sure you remove the AC power plug from the power source.

 

Using 13.6V supply mode

The 13.6V supply mode is used for low voltage batteries, maintenance charging or as a power supply for 12V batteries (14-230Ah).

 

In order to operate the 13.6V supply mode, the battery charger must not be connected to the battery.

 

CAUTION: USE THIS MODE WITH CARE

Both the spark proof and reverse polarity safety features are disabled.  Pay close attention to the polarity.  Do not allow the positive and negative battery clamp or eyelet terminal connectors to touch or connect to each other as the battery charger could generate sparks.  Check the polarity of the battery terminal before using this mode.

 

TO OPERATE THE 13.6V SUPPLY MODE, FOLLOW THESE STEPS:

  • Confirm that the AC power plug is plugged into an electrical outlet, the battery charger is not connected to the battery and you have a 12V battery. This mode is for 12V batteries only.
  • Check the polarity of the battery terminals. Make sure you understand which battery terminal is positive and which one is negative.
  • Without a battery attached, press and hold the mode button for three (3) seconds until the Red LED illuminates, indicating the 13.6V supply mode is initiated.
  • Paying close attention to the polarity (positive to positive, negative to negative) attach the battery clamps or eyelet terminal connectors to the battery,  starting with the positive cable first ( negative first, if a positive ground system)
  • When finished, press the mode button one (1) time to exit the 13.6 V supply mode and return the battery charger to standby mode.

 

USING 16V BOOST MODE

The 16V boost mode is used to recover battery capacity from a stratified (sulphated) 12 battery (14-230Ah).

 

In order to operate the 16V boost mode, the battery charger must be connected to the battery.

 

CAUTIONS: USE THIS MODE WITH CARE

This mode uses a high voltage and may cause some water loss in wet (flooded) cell batteries.  Be advised, some batteries and electronics may be sensitive to high charging voltages. For optimal results, take the battery through a full charge cycle, bringing the battery to full charge, before using this mode.  To minimize risks to electronics, disconnect the battery before using this mode.

 

 

TO OPERATE THE 16V BOOST MODE, FOLLOW THESE STEPS:

  • Confirm you have a 12V battery. This mode is for 12V Batteries only.
  • Attach the battery clamps or eyelet terminal connectors to the battery, starting with the positive cable first (negative first, if a positive ground system). If you have accidentally reversed the polarity, an error LED (orange) will illuminate. The battery charger has an internal safety feature to protect the battery charger from damage if this situation should occur.  Reverse the connections to clear the error LED and proceed to the next step.
  • Connect the battery charger’s AC power plug into a suitable electrical outlet. Do not face the battery when making this connection.
  • With a battery attached, press and hold the mode button for three (3) seconds until the Red LED illuminates, indicating the 16V boost mode is selected. After five (5) seconds, the Red LED will begin blinking indicating the 16V boost mode has been initiated.
  • When finished, press the mode button one (1) time to exit the 16V boost mode and return the battery charger to standby mode.

 

CHARGE MODES

The G7200 is equipped with six (6) charging modes, 12V norm, 12V COLD/AGM, 24V Norm, 24V COLD/AGM, 13.6 Supply and 16V boost.  Before selecting a charge mode, it is important to understand the differences and the purpose of each mode. The charge modes are explained below:

 

MODE

EXPLANATION

12V NORM

14.4V

14-230Ah

7.2A (7200mA)

Red LED

The “normal” (NORM) charge mode is for charging 12V Wet Cell, Maintenance free and Cell batteries.  If you are unsure of the chemistry of your battery, use the norm charge mode. When selected, a Red LED will illuminate.

12V COLD/AGM

14.7V

14-230Ah

7.2A (7200mA)

Blue LED

The COLD/AGM charge mode is for charging 12V batteries in cold weather and AGM (also known as “spiral wound”) batteries.  If a battery’s (Wet, Gel, MF or AGM) temperature is below 32˚F (0˚C), use the COLD/AGM charge mode. If you are unsure of the chemistry of your battery, do not use this charge mode, and use the norm charge mode instead. When selected, a Blue LED will illuminate.

24V norms

28.8V

14-120Ah

3.6A (3600mA)

Red LED

The “normal” (NORM”) charge mode is for charging 24V Wet Cell, Maintenance free and Gel Cell batteries. If you are unsure of the chemistry of your battery, use the NORM charge mode. When selected, a Red LED will illuminate.

24V COLD/AGM

29.4V

14-120Ah

3.6A (3600mA)

Blue LED

The COLD/AGM charge mode is for charging 24V batteries in cold weather and AGM (also known as “spiral wound”) batteries. If a battery’s (Wet, Gel, MF or AGM) temperature is below 32˚F (0˚C), use the COLD/AGM charge mode.  If you are unsure of the chemistry of your battery, do not use this charge mode, and use the norm charge mode instead.  When selected, a blue LED will illuminate.

 

The 13.6V supply and 16V boost charge modes are highly specialized charging modes, as indicated by the grey box on the user interface.  These charge modes should be used with cautions.  It is extremely important you read and understand these charge modes before operating.  The 13.6 supplies and 16V boost are 16V boost charge modes are explained below:

MODE

EXPLANATION

13.6V Supply

13.6V

14-230Ah

5A (5000mA)

Red LED

The 13.6V supply mode is used for low voltage batteries, maintenance charging or as a power supply. The 13.6 supply provides a constant voltage of 13.6V at 5A (5000mA).  For low voltage batteries, the 13.6V supply mode will increase the battery voltage (regardless of the starting voltage) to a point where the battery charger can perform a normal charge cycle.

 

For maintenance charging, the 13.6 supply mode will provide a “float” charge for larger capacity batteries. As a power supply (hence, supply), the 13.6V supply mode can be used to power equipment that requires 13.6 at 5A (5000mA).  This mode has an overload protection features at 6A (6000mA) max.  The 13.6V supply mode can also be used as a power supply to act as a battery when changing or replacing a battery.  When selected, a Red LED will illuminate.  For use with 12V batteries only.

16V Boost

16.5 V

14-230Ah

1.5A (1500mA)

Red LED

The 16V boost mode is used to recover battery capacity from a stratified (sulphated) battery by applying a specialized high 16.5V (17V max) voltage to soften and melt down sulphate from the battery plates so that the material becomes usable again.  When selected, a Red LED will illuminate.  FOR USE WITH 12V BATTERIES ONLY.

 

CHARGING STEPS

Step 1: Diagnostics

Checks the battery voltage to make sure battery connections are good and the battery is in a stable condition before beginning the charge process

 

Step 2: Recovery

Initializes the recovery process, if needed, for deeply discharged or sulphated (desulfation) batteries by pulsing small amounts of current.

 

Step 3: Soft Start

Begins bulk charging process with a gentle (soft) charge.

 

Step 4-7: bulk

The bulk charging process continues using Max Rate, High Rate, medium rate and low rate charges and returns 80% of battery capacity, indicated by the 25%, 50% and 75% charge LEDs.

 

Step 8: Absorption

Brings the charge level to 90%.  The battery charger will deliver small amounts of current to provide a safe, efficient charge and limit battery gassing.

 

Step 9: Trickle

Battery is fully charged and ready to use, indicated by the 100% charge LED being a solid green.  In this step, the battery charger will only deliver enough current to keep the battery full.  If the battery tells the charger that more current is needed, the battery charger will switch to maintenance.

 

Step 10: Maintenance

Continuously monitors the battery voltage to determine if a maintenance charge should be initiated.  If the terminal voltage falls below 12.8 (12V) and 25.6V (24V), the charger will start the maintenance cycle until voltage reaches 14.4V (12V) and 28.8V (24V) and then discontinues the charge cycle.  The cycle between trickle and maintenance is repeated indefinitely to keep the battery at full charge, without overcharging.  The battery charger can be left connected indefinitely.

 

Step 11: 13.6V Supply

The 13.6V supply mode is used for low voltage batteries, maintenance charging or as a power supply.

 

Step 12: 16V boost

The 16V Boost mode is used to recover battery capacity from a stratified (sulphated) battery by applying a specialized high 16.5V (17V Max) voltage to soften and melt down sulphate from the battery plates so that the material becomes usable again.

 

CHARGING TIMES

The time required for the G7200 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.

 

BATTERY SIZE (AH)

APPROX.TIME TO CHARGE IN HOURS

12V

24V

14

1.5

3.5

25

3.0

6.0

30

4.0

7.5

40

5.0

10.0

50

6.0

12.5

60

7.5

15.5

100

12.5

25.0

120

15.5

30.0

180

22.0

-

230

29.0

-

 

  • NOTE: the above table is for reference purposes only. Actual data may differ due to battery conditions.  The time required for the G7200 to charge a normally discharged battery is based on an average DOD of 50%.

 

TECHNICAL SPECS

Input voltage AC:                     220-240AC, 50/60HZ

Working voltage AC:              220-240VAC, 50/60HZ

Input Current:                           1300mA RMS Max

Efficiency:                                   85% Approx

Power:                                         150W Max

Charging Voltage:                    14.4/28.8V (norm) 14.7/29.4V (cold/agm), 13.6V (supply), 16.5V (boost)

Charging current:                     7200mA (12V), 3600mA (24V), 5000mA (supply), 1500mA (boost)

Back current drain:                  <5mA

Ripple:                                         <2%

Charger type:                            12 Step, fully Automatic, Switch-mode

Type of batteries:                    12V & 24V Lead-Acid

Battery Chemistries:              Wet, Gel, MF & AGM

Battery Capacity:                     14-120Ah (24V)

                                                         14-120Ah (12V)

Housing protection:               IP65 (For Indoor use only)

Cooling:                                        Natural Convection

Noise level:                                <50 dB

Dimensions (L x W x H):       8.9 x 3.8 x 2.4 inches

Weight:                                       1.7 Pounds

Approval:                                    GS/ BS/ SAA/ SABS EMC & EMI, COC and NRCS LOA

 

LIMITED WARRANTY

The NOCO Company (“NOCO”) warrants that its battery charger 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 “warrant period”).  For defects reported during the warranty period, NOCO will, at its discretion, and subjects to NOCO’s technical support analysis, either repair or replace, for the fees set forth below, any product manufactured by NOCO that contains such a defect.  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.

 

THE FOREGOING LIMITED WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES NOT EXPRESSLY SET FORTH HEREIN, WHETHER EXPRESS OR IMPLIED BY OPERATION OF LAW OR OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

 

NOCO’S LIABILITY UNDER THIS LIMITED WARRANTY IS EXPRESSELY LIMITED TO REPLACEMENT (IN THE FORM AND UNDER THE TERMS ORIGINALLY SHIPPED), OR TO REPAIR, WHETHER SUCH CLAIMS ARE FOR BREACH OF WARRANTY OR FOR NEGLIGENCE.  NOCO SHALL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, OR SPECIAL LOSSES, DAMAGES OR EXPENSES OF ANY KIND, INCLUDING, WITHOUT LIMITATION, ANY SUCH LOSSSES, DAMAGES, OR EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM THE SALE, HANDLING, OR USE OF THE PRODUCT FROM ANY OTHER CAUSE RELATING THERETO, OR FROM PERSONAL INJURY OR LOSS OF PROFIT.

 

Some states do not allow the exclusion or limitation of incidental or consequential damages or length of an implied warranty so the above limitation(s) or exclusion(s) may not apply.  This limited warranty gives you specific legal rights and you may also have other legal rights which vary from state to state.

 

The limited warranty is made to the original purchaser from NOCO and does not extend to any other person or entity and is not assignable.  It is the obligation of the original purchaser to forward the product, with the proof of purchase and completed product registration, prepaid, to NOCO. All warranties should be sent to:

 

THE NOCO Company

Attn: Warranty Department

30339 Diamond Parkway, #102

Glen willow, OH 44139 USA

 

 

THE COSTS OF TRANSPORTING PRODUCTS TO NOCO FOR WARRANTY SERVICE IS THE RESPONSIBILITY OF THE ORIGINAL PURCHASER.

 

THIS LIMITED WARRANTY IS VOID UNDER THE FOLLOWING CONDITIONS:

  • The products is misused, subjected to careless handling, or operated under conditions of extreme temperature, shock, or vibration beyond NOCO’s recommendations for safe and effective use.
  • The product has not been installed, operated, or maintained in accordance with approved procedures
  • The product is disassembled, altered, or repaired by anyone, except NOCO.
  • The electrical connections to either the AC input or the DC output of the charger are modified without the express written consent of NOCO.
  • The product is subject to improper storage or accident.
  • The original purchaser fails to complete and submit the product registration at geniuschargers.com

THIS LIMITED WARRANTY DOES NOT COVER:

  • Normal wear and tear
  • Cosmetic damage that does not affect functionality
  • Products where the NOCO serial number is missing, altered or defaced.

 

LIMITED WARRANTY FEES

These fees apply only to products during the warranty period. The limited warranty is void either by elapsed time from date of purchase or from the conditions listed earlier in this document.  Return products with the appropriate documentation along with a check for the applicable fees, as set forth below.  Make checks payable to the NOCO Company.

 

 

WITH RECEIPT

<2.5 YEAR  2.5-5 YEAR

NO RECEIPT

ANYTIME

G750

$0.00

$9.95

$13.95

G1100

$0.00

$13.95

$18.95

G3500

$0.00

$16.95

$23.95

G7200

$0.00

$30.95

$42.95

G26000

$0.00

$87.95

$122.95

 

The Warranty fee structure may change without notice.  Please refer to our website for the current fee structure.

REGISTER MY BATTERY CHARGER

You must register the battery charger in order to validate the limited warranty.

 

To register your products, please visit:

Geniuschargers.com/register

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