NOCO GX2440, GX3626, GX4820 - GX Series Industrial Battery Chargers Manual

What's In The Box

• GX Series Smart Charger
• AC Cable
• User Guide
• Information Guide and Warranty

About the Device

The NOCO Genius^® GX Series of chargers represents some of the most innovative and advanced technology on the market, making each charge simple and easy. The GX is designed for charging all types of 24V, 36V or 48V lead-acid and lithium-ion battery systems, including Wet (Flooded), Gel, MF (MaintenanceFree), CA (Calcium), EFB (Enhanced Flooded Battery), AGM (Absorption Glass Mat), and LIB (Lithium Ion) batteries. It is suitable for charging battery capacities from 25 to 500 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 GX Series Chargers have four (4) external holes for mounting. Make sure there are no obstructions behind the mounting surface. It is important to keep in mind the distance to the battery. Allow for 12-inches (304mm) of slack in cables between connections.

Charging Modes

The GX Series Chargers have seven (7) modes: Standby, NORM, COLD/AGM, AGM+, LI-ION, REPAIR and SUPPLY. 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 your full attention before selecting. 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:

Basic Charging Modes

Voltage and current depend on model of charger. Specifications for each model are listed below.

ALWAYS VERIFY THE VOLTAGE OF A BATTERY SYSTEM BEFORE ATTEMPTING TO CHARGE.
ONLY USE THE GX SERIES CHARGER THAT IS DESIGNED FOR THE SAME VOLTAGE AS YOUR BATTERY SYSTEM.

Advanced Charging Modes

Advanced Charge Modes are modes that require the users full attention when selecting.

Using AGM+

[Press & Hold]
AGM+ charge mode is designed for advanced AGM batteries only. Advanced AGM batteries are a new battery technology. These batteries accept a higher than normal charging voltage. AGM+ charge mode is NOT suitable for traditional AGM batteries. Consult the battery manufacturer before using this mode.

USE THIS MODE WITH CARE. THIS MODE IS FOR LEAD-ACID ADVANCED AGM BATTERIES ONLY. THIS MODE USES A HIGH CHARGING VOLTAGE AND MAY CAUSE SOME WATER LOSS IN WET (FLOODED) CELL BATTERIES OR OVERCHARGE IN SOME BATTERIES.

Using LI-ION

[Press & Hold]
LI-ION charge mode is for lithium-ion batteries only, including lithium iron phosphate batteries.

THIS MODE IS FOR LITHIUM BATTERIES 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 BATTERIES MAY BE UNSTABLE AND UNSUITABLE FOR CHARGING.

Using Repair

[Press & Hold]
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 Repair in attempt to reverse these problems. For optimal results, take the battery through a full charge cycle, bringing the battery to full charge, before using this mode. Repair can take up to four (4) hours to complete the recovery process and will return to Standby when completed.

USE THIS MODE WITH CARE. THIS MODE IS FOR LEAD-ACID BATTERIES ONLY. THIS MODE USES A HIGH CHARGING 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. TO MINIMIZE RISKS TO ELECTRONICS, DISCONNECT THE BATTERY BEFORE USING THIS MODE.

Using Supply

[Press & Hold]
Supply converts the charger to a constant current, constant voltage DC power supply. To enter Supply Mode, the charger must not be connected to the battery.

THIS MODE IS FOR LEAD-ACID BATTERIES ONLY. PRIOR TO USE, READ YOUR DEVICE MANUAL TO DETERMINE IF IT IS SUITABLE FOR USE WITH THIS MODE. BOTH THE SPARK PROOF AND REVERSE POLARITY SAFETY FEATURES ARE DISABLED IN THIS MODE. DO NOT ALLOW THE POSITIVE AND NEGATIVE BATTERY CLAMP OR EYELET TERMINAL CONNECTORS TO TOUCH OR CONNECT TO EACH OTHER AS THE CHARGER COULD GENERATE SPARKS. CHECK THE POLARITY OF THE BATTERY TERMINALS BEFORE USING THIS MODE.

Cable Connections

The GX Series Chargers have AC and DC connection ports that are designed to allow the user to choose custom cables to fit the desired application. Both the AC and DC connection ports are labeled to inform the user the proper way to install custom cables.

AC Input Connection Port

The AC Input Connection Port requires line (black), return (white) and ground (green) connections. The unit must be grounded for safe operation. 16AWG minimum wire gauge is required. Make sure all connections are securely tightened and insulated from each other before operation. To increase the charger's waterproofing, completely seal the entire connection with electric sealant.

AC Input Connection Port

DC Output Connection Port

The DC Out Connection Port requires positive (red), and negative (black) connections. 10AWG minimum wire gauge is required. Make sure all connections are securely tightened and insulated from each other before operation. To increase the charger's waterproofing, completely seal the entire connection with electric sealant.

DC Output Connection Port

Inhibit Port (Optional For Operation)

The Inhibit Port contains a Relay rated at 20A. When the Charger has AC power, the relay will close allowing current flow. When the charger is removed from AC power, it takes approximately 15 seconds for the capacitors to discharge and the relay to open.

Remote LEDs Port (Optional For Operation)

The Remote LEDs Port can be used to connect LEDs for easy monitoring when the charger's LEDs are not accessible. The port supports two LEDs, reversing polarity to change from "Charging" to "Charged."

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.

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 terminal 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 LEDs 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.
   
   User Interface

Understanding Charge LEDs

The charger has four (4) Charge LEDs per bank - 25%, 50%, 75% and 100%. These Charge LEDs indicate the connected battery(s) state-of-charge (SOC). See the explanation below:

The RED LEDs will gradually spin slower as the battery charges.

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).

Error	Reason/Solution
Single Flash	Battery will not hold a charge. Have battery checked by a professional.
Double Flash	Possible battery short. Have battery checked by a professional.
Triple Flash	Battery voltage is too high for the selected charge mode. Check the battery and charge mode.
Quadruple Flash	Abnormal AC grid power: VAC <85V or >250V, or Frequency <45Hz or >65Hz.
Error LED Solid Red	Reverse polarity. Reverse the battery connections.
Standby Solid Orange	Battery voltage is too low for charger to detect. Verify connection and mode selection, if still not working use Supply Mode to raise battery voltage.
	Memory Returns to last selected mode when restarted
	Interactive Alters the charging process based on organic battery feedback
	Recovery 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 Charges two times faster than traditional battery chargers
	Compensation Adjusts for varying A/C line voltage for consistent charging
	Rugged Dirt, water, UV, impact and crush resistant
	Compact High-frequency energy conversion for ultra-compact, lightweight and portable charger
	Start-Stop Counteracts increased cyclic energy demands placed on batteries in microhybrid vehicles
	Firewall Multi-level safety barrier that prevents abnormal and unsafe conditions
	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 LEDs dynamically track the 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
	Thermal Monitor Internal temperature sensors adjust charge based on ambient climate
	Opportunity Charging Designed to rapidly charge batteries in applications where charging is intermittent between use

Charging Steps

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.

3. Recovery
   Initializes the Recovery desulfation process (if needed) for deeply discharged or sulfated batteries by pulsing small amounts of current.
4. Initialize
   Starts the charging process with a gentle (soft) charge.

5&6. Opportunity & Bulk
Begins with opportunity charging at a high current, then steps down to the Bulk charging process based on the condition of the battery and returns 80% of the battery's capacity.

7. 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.
8. Optimization
   Finalizes the charging process and brings the battery to maximum capacity. In this step, the charger utilizes multilayered 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.
9. 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 of overcharging.

Technical Specifications

Contacting NOCO

Phone: 1.800.456.6626
Email: support@no.co
Mailing Address: 30339 Diamond Parkway, #102 Glenwillow, OH 44139
United States of America

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.

Documents / Resources

References

• NOCO
• NOCO

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