NOCO Genius GEN4 On-Board Battery Charger Instruction Manual

1. Introduction

The NOCO Genius GEN4 is a sophisticated 4-bank, 40-amp smart marine charger and battery maintainer designed for 12-volt lead-acid batteries. Its robust, waterproof construction makes it ideal for demanding marine environments. This manual provides essential information for the proper setup, operation, and maintenance of your GEN4 charger.

Figure 1: NOCO Genius GEN4 On-Board Battery Charger

2. What's in the Box

Upon unpacking, ensure all components are present:

• GEN4 On-Board Battery Charger

3. Setup and Installation

The NOCO Genius GEN4 is designed for easy installation directly onto various applications, particularly in marine environments. It replaces older, heavier charger models with a more compact and efficient design.

3.1 Replacing an Existing Charger

If replacing an older charger, first ensure all power to the existing unit is disconnected. Carefully remove the old charger, noting its connections. The GEN4 is significantly lighter and more compact than many older models, simplifying the mounting process.

Figure 2: GEN4 with individual bank output cables

3.2 Wiring Connections

The GEN4 features four independent banks, each providing 10 amps of charging power. Each bank has dedicated positive and negative leads that connect directly to individual 12-volt batteries. This allows for simultaneous and independent charging of up to four batteries.

Figure 3: Detailed view of GEN4 charging banks

For AC input, the charger requires a 120V AC connection. It is recommended to use a 20-amp rated outlet to ensure sufficient power delivery, as the charger can draw up to 1920 watts at its maximum output (40 amps total output at 12 volts, multiplied by 120V input voltage for wattage calculation, 40A * 12V = 480W output, 1920W input for 40A output at 12V, assuming 25% efficiency loss, 480W / 0.25 = 1920W). Ensure all connections are secure and properly insulated to prevent shorts and maintain the unit's waterproof integrity.

4. Operating Instructions

The GEN4 is a fully-automatic smart charger. Once connected to batteries and a power source, it will automatically begin its charging and maintenance cycle. Each bank has indicator lights to show the charging status:

• Solid Red: Battery is currently charging.
• Solid Green: Battery is fully charged and in maintenance mode.

The charger is designed to safely charge all types of 12-volt lead-acid batteries, including wet, gel, AGM, and deep-cycle batteries, without risk of overcharge.

5. Maintenance

The NOCO Genius GEN4 features a rugged and waterproof construction, rated IP68 and NEMA 6P, allowing it to withstand submersion down to 3 meters. This design minimizes the need for extensive maintenance. Periodically inspect the charger and its connections for any signs of damage or corrosion. Keep the unit clean and free from debris to ensure optimal performance and longevity.

6. Troubleshooting

6.1 Charger Not Turning On or Charging

If the charger is not turning on or providing a charge to the batteries, first verify that the AC power source is active and providing 120V. Check all connections to ensure they are secure. If the unit is getting excessively hot without providing output, this may indicate an internal malfunction. In such cases, discontinue use and refer to the warranty information for support.

6.2 Power Requirements

Ensure the power outlet used can supply the necessary amperage. For the GEN4's 40-amp total output, a 20-amp 120V AC outlet is recommended to handle the maximum power draw. Using an undersized outlet may prevent the charger from operating correctly or trigger circuit breakers.

7. Specifications

Figure 4: Product Dimensions

8. Warranty and Support

The NOCO Genius GEN4 On-Board Battery Charger is backed by a 5-year limited warranty. For warranty claims or technical support, please refer to the contact information provided in your product packaging or visit the official NOCO website.