SOLAR PL6800 Fleet Battery Charger User Manual

SOLAR PL6800 Fleet Battery Charger

Product Information

• Product Name: SOLAR PL6800
• Model Number: PL6800
• Part Number: 141-680-000
• Manufacturer: Clore Automotive

Chemical Warning: This product contains chemicals, including Vinyl-Chloride, Styrene, and Acrylonitrile, which are known to the State of California to cause cancer. For more information, visit www.P65Warnings.ca.gov

Product Usage Instructions

1. NEVER attempt to charge a marine (boat) battery while the boat is on or near the water. The boat must be on a trailer and located indoors before attempting to charge its battery(s). Follow the boat manufacturer’s battery charging instructions exactly.
2. NEVER set the charger, output cable or clamps, or AC power cord plug in water or on wet surfaces.
3. NEVER use this charger on a pier or dock to avoid the risk of electric shock.
4. NEVER attempt to plug in or operate the battery charger with defective or damaged wires, power cord, or power cord plug. Have these parts been replaced by qualified personnel immediately?
5. NEVER attempt to plug in the charger or operate its controls with wet hands or while standing in water.
6. NEVER alter the AC power cord or power cord plug provided with the battery charger.
7. NEVER use an attachment not recommended or sold by Clore Automotive for use with this specific model battery charger.
8. NEVER operate this battery charger if it has received a sharp blow, been dropped, or is similarly damaged. Has it been inspected and/or repaired by qualified service personnel?
9. NEVER disassemble this battery charger. Take it to qualified service personnel for service or repair.
10. ALWAYS plug in and unplug the AC power cord by grasping the power cord plug, NOT THE POWER CORD.
11. ALWAYS unplug the battery charger from the AC outlet before attempting any cleaning or maintenance.
12. An extension cord should only be used if absolutely necessary. Ensure it is properly wired and in good electrical condition.
13. NEVER operate this battery charger near fuel tanks or gas cylinders to avoid the risk of explosion.

Note: Please refer to the complete instruction manual for detailed information and additional safety guidelines.

WARNING   Failure to follow instructions may cause damage or explosion, always shield your eyes. Read the entire instruction manual before use

Warning : This product can expose you to chemicals, including Vinyl- Chloride, Styrene, and Acrylonitrile, which are known to the State of California to cause cancer. For more information go to www.P65Warnings.ca.gov Please read and retain these instructions for the continued safe use of your new charger. This manual contains important safety information. DO NOT OPERATE this equipment UNTIL YOU HAVE READ this safety summary!

SAFETY SUMMARY
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions for Model No. PL6800.

WARNING

• Read these instructions completely before using the SOLAR Battery Charger and save them for future reference. Before using the SOLAR Battery Charger to charge a battery, read these instructions and the instruction manual/safety information provided by the car, truck, boat, or equipment manufacturer. Following all manufacturers’ instructions and safety procedures will reduce the risk of accidents.
• Working around lead-acid batteries may be dangerous. Lead-acid batteries release explosive gases during normal operation, charging, and jump-starting. Carefully read and follow these instructions for safe use. Always follow the specific instructions in this manual and on the SOLAR Battery Charger each time you use the SOLAR Battery Charger.
• All lead-acid batteries (cars, trucks, and boats) produce hydrogen gas which may violently explode in the presence of fire or sparks. Do not smoke, use matches or a cigarette lighter while near batteries. Do not handle the battery while wearing vinyl clothing because static electricity sparks are generated when vinyl clothing is rubbed. Review all cautionary material on the SOLAR Battery
• Charger and in the engine compartment.
• Always wear eye protection, appropriate protective clothing, and other safety equipment when working near lead-acid batteries. Do not touch your eyes while working on or around lead-acid batteries.
• Always store clamps away from each other or common conductors. Improper storage of clamps may cause the clamps to come in contact with each other, or a common conductor, which would be hazardous if the charger was plugged into an AC outlet.
• Use extreme care while working within the engine compartment, because moving parts may cause severe injury. Read and follow all safety instructions published in the vehicle’s Owner’s Manual.
• Batteries being charged with the SOLAR Battery Charger unit likely contain liquid acids which are hazardous if spilled.

WARNING : Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.
NOTE: This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. This Class A industrial apparatus complies with Canadian ICES-003.

WARNING – Shock Hazards

1. NEVER attempt to charge a marine (boat) battery while the boat is on or near the water. A boat must be on a trailer and located indoors before attempting to charge its battery(s). The boat manufacturer’s battery charging instructions must be followed exactly.
2.  NEVER set the charger, output cable or clamps, or AC power cord plug in water or on wet surfaces.
3. NEVER use this charger on a pier or dock. The charger could fall into the water, creating an electric shock hazard.
4. NEVER attempt to plug in or operate the battery charger with defective or damaged wires, power cord, or power cord plug. Have any of these parts that are defective or damaged replaced by qualified personnel IMMEDIATELY.
5. NEVER attempt to plug in the charger or operate its controls with wet hands or while standing in water.
6. NEVER alter the AC power cord or power cord plug provided with the battery charger.
7. NEVER use an attachment not recommended or sold by Clore Automotive for use with this specific model battery charger. Use of such attachment may result in a risk of fire, electric shock or injury to persons.
8. NEVER operate this battery charger if it has received a sharp blow, been dropped, or similarly damaged, until after being inspected and/or repaired by qualified service personnel.
9. NEVER disassemble this battery charger. Take the battery charger to qualified service personnel when service or repair is needed. Incorrect reassembly may result in a risk of electric shock or fire.
10.  ALWAYS plug in and unplug the AC power cord by grasping the power cord plug, NOT THE POWER CORD, to reduce the risk of damaging the power cord.
11.  ALWAYS unplug the battery charger from the AC outlet before attempting any cleaning or maintenance. Turning the charger’s control(s) OFF, alone, will not remove all electricity from the charger, and will not reduce this risk.
12.  An extension cord should not be used unless absolutely necessary. The use of an improper extension cord could result in a fire or electric shock. If an extension cord must be used, make sure that:
    • The pins on the plug of the extension cord are the same number, size, and shape as those of the plug on the charger;
    • That extension cord is properly wired and in good electrical condition; and
    • That the wire size is large enough for the length of the cord as specified below Length of cord in feet: 10 25 50 AWG size of cord: 12 10 8

WARNING – Risk of Explosive Gases

1. WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASSES DURING NORMAL OPERATIONS AND, AT AN EVEN HIGHER LEVEL, DURING CHARGING. IF ANYTHING IS ALLOWED TO IGNITE THESE GASSES, THE BATTERY MAY EXPLODE, SENDING PIECES OF THE BATTERY AND EXTREMELY CAUSTIC BATTERY ACID OUT IN ALL DIRECTIONS AND WITH EXTREME FORCE. SINCE JUST THE SLIGHTEST SPARK IS SUFFICIENT TO IGNITE THESE GASSES, IT IS OF UTMOST IMPORTANCE THAT YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY, BEFORE USING YOUR BATTERY CHARGER.
2. NEVER operate this battery charger near any fuel tanks or gas cylinders. This charger can produce sparks that could ignite gasses and cause an explosion.
3. NEVER attempt to permanently mount this battery charger on a marine or recreational vehicle.
4. NEVER attempt to connect this charger’s output cables directly to the battery(s) in the bilge or engine compartment of a boat. Follow the boat manufacturer’s battery charging instructions exactly.

WARNING – Battery Explosion Hazards

1. NEVER connect both battery charger clamps directly to the two posts of the same battery. See Operation Instructions for connection procedures.
2. NEVER allow the DC output clamps to touch each other.
3. ALWAYS be extra cautious to reduce the risk of dropping a metal object, such as a tool, onto or near the battery. Doing so could produce a spark or short circuit the battery or other electrical part that could cause an explosion.
4. NEVER operate the battery charger in a closed-in area or restrict ventilation in any way.
5. ALWAYS make sure the area around a battery is well-ventilated while it is being charged. Gas can be forcefully blown away by using a piece of cardboard or other non-metallic material as a fan.
6. ALWAYS make sure that the AC power cord is unplugged from the AC outlet or extension cord BEFORE connecting or disconnecting the battery charger clamps, to prevent arcing or burning.
7. ALWAYS locate the battery charger as far away from the battery as the DC output cables will permit.
8. ALWAYS twist or rock charger clamps back and forth several times on the battery post and the other point of connection at the time of initial connection. This helps keep the clamps from slipping off their points of connection which helps reduce the risk of sparking. DO NOT rock the clamp connected to the battery post AFTER the second connection (at a point away from the battery) is made or sparking may occur at the battery post.
9. ALWAYS check the cable and wire connections at the battery(s) for tightness BEFORE starting to charge. A loose connection can cause sparks or excessive heating which could cause a battery explosion.
10. ALWAYS make sure the battery compartment is open and well-ventilated before charging.

WARNING – Moving Parts Hazards

1. NEVER connect the battery charger clamps to a vehicle when the engine is running.
2. ALWAYS stay clear of fan blades, fan belts, pulleys and other moving engine parts when working near an engine. Moving engine parts can cause severe personal injury, including dismemberment.
3. ALWAYS make sure that the battery charger cables and clamps are positioned so they will not come in contact with any moving engine parts.
4. NEVER wear loose clothing or long hair around moving parts because they may get caught and cause severe injury or death.

WARNING – Burn Hazards

1. NEVER lean on or rest against the engine or cooling system parts when the vehicle is running.
2. ALWAYS stay clear of the cooling system, engine, and engine manifold. These engine components get very hot and retain heat for a long time. Touching any of these components can cause severe burns.
3. Never connect the clamps to a battery before confirming that the output cables are securely connected to the unit.

PERSONAL PRECAUTIONS

1. Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
3. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near the battery.
4. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood the eye with running cold water for at least 10 minutes and get medical attention immediately.
5. NEVER smoke or allow a spark or flame in the vicinity of the battery or engine.
6. Be extra cautious to reduce risk of dropping a metal tool onto the battery. It might spark or short-circuit a battery or another electrical part that may cause an explosion.
7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or other jewelry to metal, causing a severe burn.
8. Use a charger for charging LEAD-ACID batteries only. It is not intended to supply power to a low-voltage electrical system other than in a starter-motor application. Do not use a battery charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage to property.
9. NEVER charge a frozen battery, as battery explosion can result

INTRODUCTION

Description
This battery charger is designed to handle the majority of your charging and starting needs. It features:

• Automatic Multi-Phase Charging mode for easy operation.
• The ability to properly charge multiple battery types, including Flooded, AGM and Spiral Wound batteries.
• Multiple Charge Rates for various battery sizes.
• Power supply mode to maintain system voltage during reprogramming, on-vehicle repairs, or component diagnosis.
• Heavy-Duty clamps for strong, secure battery connections and efficient transfer of power to the vehicle.
• Heavy-Duty Construction for long, trouble-free life.

How Batteries Charge
A battery charger does not force current into a battery – it makes a specific amount of current available to the battery and the battery draws as much of it as it needs, up to or slightly greater than the rated output current capability of the charger. The closer a battery is to zero capacity (dead battery), the more charging current it will want to draw. When charging begins, on a dead battery, the charger will typically supply current at or very near the nominal chosen charging rate, and then move to a reduced rate of current as the battery becomes more fully charged. Keep in mind, a charger’s display shows the amount of current being drawn from the charger by the battery, not what the charger is capable of delivering. Note: A slow, intermittent bubbling sound may be heard coming from the battery during the charging process. This is a normal condition and just another indicator the battery is being charged. To reduce the risk of battery overcharging, it is important to thoroughly read this entire instruction manual.

How a Power Supply Functions
Your unit features two separate working modes: automatic battery charging mode and power supply mode. These are two very different modes. A power supply is used to hold the voltage of the electrical system on a vehicle at a constant voltage for various service/maintenance functions. These include programming events, on-vehicle repairs, and other applications where it is detrimental for the system voltage to drop below a specific threshold. In power supply mode, your unit will provide power to the vehicle’s electrical system so that system voltage remains at a steady level (as directed by you during power supply mode set-up) despite load changes the system experiences (up to 100A) over an extended period of time.
NOTE: Power supply mode utilizes the vehicle’s battery to improve response times to load changes. As such, it is important to ensure the vehicle’s battery is in good condition and fully charged prior to initiating power supply mode.

Spark Prevention
Make sure no sparks or flames occur near the battery, especially during charging. It takes very little to ignite the explosive gasses produced by a lead-acid battery during the charging process. Read, understand, and follow the safety information provided in the Safety Summary section of this manual before attempting to work with or near a lead-acid battery. For more information about batteries and battery charging, contact Battery Council International at www.batterycouncil.org, and download their Battery Service Manual

PREPARATION

Charger Placement

• Place the charger in a clean, dry, stable, well-ventilated spot as far from the battery as the DC output cables permit.
• NEVER place the charger directly above the battery being charged – gasses from the battery will corrode and damage the charger.
• NEVER allow battery acid to drip on the charger when reading specific gravity or filling the battery.
• NEVER place a battery on top of the charger.
• NEVER attempt to permanently mount this battery charger on a marine or recreational vehicle.
• ALWAYS position the charger on the outside of a boat or recreational vehicle.
• Provide Required Power
• This battery charger requires a nominal 120V 60Hz alternating current (AC) power source. The power source must be fused at an amperage greater than or equal to the input amps rating of this charger – see back of unit for input power requirements.
• Do not plug the charger into the AC power source until told to do so in the operating instructions.

WARNING: ELECTRIC SHOCK CAN KILL!
See Safety Summary, pages 2-5. To reduce the risk of electric shock, never alter AC power cord or power cord plug provided on the charger. If it will not fit the outlet, have a proper outlet installed by a qualified electrician. Never use an adapter. The charger must be grounded to reduce risk of electric shock. The charger is equipped with an electric cord that has an equipment grounding plug. The plug must be plugged into an AC outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Extension Cords
An extension cord should not be used unless absolutely necessary. If necessary, care must be taken to select an extension cord suitable for use with your specific battery charger (see Shock Hazards in Safety Summary).

WARNING: Fire can kill, injure and cause property damage! See Safety Summary, pages 2-5. To reduce the risk of electric shock and fire, never alter the AC power cord or power cord plug provided on the charger. Never alter extension cords or extension cord plugs. Make sure the extension cord is properly wired and in good electrical condition. Make sure the wire size (American Wire Gauge or AWG) of the extension cord is large enough to handle your specific charger’s amperage requirements. This battery charger features protection against abnormally low input voltage and will safely shut the charger down if the input voltage is too low.

Battery Preparation
WARNING: Battery explosion can injure and cause property damage! Never smoke or allow a spark or flame in the vicinity of the battery or engine. See Safety Summary, pages 2-5. If it is necessary to remove the battery from the vehicle to charge it, make sure all accessories in the vehicle are off and always remove the grounded cable from the battery first. If needed, add distilled water to each cell of the battery until battery acid reaches the manufacturer’s specified level. DO NOT OVERFILL! This helps remove excessive explosive gasses from the battery. For maintenance-free batteries without caps, carefully follow the battery manufacturer’s recharging instructions.

WARNING: Battery acid can cause serious injury and property damage! See Safety Summary, pages 2-5. Always wear complete eye and clothing protection and avoid touching eyes while working near the battery. Clean battery terminals. Be careful to keep corrosion from coming in contact with the eyes. Study all of the battery manufacturer’s precautions, such as whether cell caps should be left in place or removed during charging, and the recommended rates of charge for the specific battery. If you are unable to determine the battery manufacturer’s requirements for charging, always charge the battery with cell caps in place at the lowest charging rate available. If the battery voltage cannot be determined from the information on the battery itself, refer to the owner’s manual for the product in which the battery was installed. Since the charger has an adjustable charge rate, charge the battery initially at the lowest rate.

The Ability to Charge Multiple Battery Types
Traditional battery chargers utilize basic charging controls that make them appropriate for charging only Conventional and Maintenance Free Flooded (wet) Cell batteries. Use of traditional battery chargers on AGM or other modern batteries results in suboptimal charging and potential harm to the battery being charged. PRO-LOGIX Charger models utilize advanced charging technology to deliver precise charge controls, enabling them to properly charge a wide variety of battery types. Soft Start Mode and Battery Repair Mode PRO-LOGIX Charger models utilize a proprietary advanced Multi-Phase charging process designed to optimally charge many types of batteries. One critical aspect of this proprietary process is the precise control achieved through the charging process, enabling the charger to monitor a battery’s specific reaction to the power supplied. The PRO-LOGIX charging process includes a Soft Start Mode to properly charge deeply discharged batteries and ensure that the energy from the charger is being properly incorporated into the battery. It also includes a Battery Repair Mode to attempt to restore batteries that do not properly accept charging current. The display will indicate BATTERY REPAIR by flashing the CHARGING LED and monitoring current acceptance by the battery. Battery charging time will be extended to allow the battery to recover. Both processes are fully automatic and require no intervention on the part of the operator, either to initiate the process or complete it.

Locating the Charger

1. Locate the charger as far away from the battery as DC cables permit.
2. Never place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger.
3. Never allow battery acid to drip on the charger when reading specific gravity or filling the battery.
4. Do not operate the charger in a closed area or restrict ventilation in any way.
5. Ensure that there are no obstructions to the air flow, so the internal fans can properly cool the unit.
6. Do not set a battery on top of the charger.
7.  Locate the charger at least 18” above the floor.
8. Do not place the charger where rain, snow, or other moisture could drip on it.

CONTROLS AND INDICATORS

MODE Selection Button
The Mode selection button changes the mode of operation of the charger between AUTO CHARGE mode and POWER SUPPLY mode. In Auto Charge mode, once the charging parameters have been set and the START button has been pressed, the charger will commence a proprietary, advanced multi-phase charging sequence designed to provide an optimal charge. POWER SUPPLY mode provides steady, stable power to maintain system voltage during programming events, on-vehicle repairs and
other applications where it is detrimental for system voltage to drop below a specific threshold.

SUPPLY Control Buttons
Once an operator chooses SUPPLY Mode, they are able to select the desired system voltage to be maintained. Desired voltage can be increased or decreased in 0.1V increments

CHARGE Control Buttons
Once an operator chooses CHARGE Mode, there are additional settings that must be chosen prior to commencing the charging sequence. The Type button allows an operator to choose the specific battery type to be charged, enabling the charger to provide the exact power profile for that battery type. Selectable battery types include traditional flooded batteries and AGM batteries (including Spiral Wound batteries). The Rate button allows an operator to choose the desired charge rate for each specific application. Selectable charge rates include 100A, 40A, or 10A charge rates. The START button is used to commence each function once all of the functional parameters have been set to the desired values. The START button can also be used to discontinue any function once it has commenced. LED Status Lights LED lights in the control panel indicate which functional mode the charger is currently set to, as well as the current status of the chosen function once the function has commenced. In addition, each function mode features error LEDs to alert the operator to unsafe operating conditions, including battery faults and reverse polarity connections.

Choosing a Charging Rate

Choose a charging rate that is appropriate for the size and type of battery being charged. Use the battery manufacturer’s specific instructions or see the guidelines below.
Typical rates are: Small Motorcycle/Powersport 5 Amps or less (not applicable to this charger) Lawn Mower/Tractor 5 Amps or less (not applicable to this charger) Deep Cycle 15 Amps or less Maintenance Free Automotive or Marine Cranking 40 Amps or less Heavy Duty Commercial 60 Amps or less Heavy-Duty Commercial (2+ Batteries) 100 Amps or less Do not exceed the maximum charge rate recommended by the battery manufacturer or the chart above.

Choosing a Battery Type Setting
PRO-LOGIX Charger models utilize advanced charging technology to deliver precise charge controls, enabling them to properly charge a wide variety of battery types.

• For Conventional and Maintenance Free Flooded (wet) Cell batteries: Choose STANDARD (STD).
• For AGM batteries: Choose AGM.
• For Spiral Wound Batteries: Choose AGM.

For batteries identified as Deep Cycle or Marine batteries, determine the construction of the battery. Is it a Wet cell, AGM or Spiral Wound type of construction? Battery construction will determine the proper battery type selection.

Pre-Charge Battery Activation
Some modern batteries can cause charging problems if they have been deeply discharged. The plates in these batteries can begin sulfating quickly, forming a barrier to accepting a charge. This condition will be indicated by an extremely low (or zero) ammeter reading, indicating that the battery is not accepting current from the charger. A deeply discharged battery such as this may take as long as 4 to 8 hours before it will accept a charge. The Automatic Charging mode attempts to detect batteries with this condition (see Battery Repair Mode in PREPARATION) and automatically adjusts for it.

OPERATION

Operating Instructions
ATTENTION: Do not attempt to operate this battery charger until you have read and understood the entire Safety Summary provided in this manual. Connecting to Batteries Installed in Vehicles

ATTENTION: Do not plug the charger power cord into the AC power source or set any of the charger’s controls
until told to do so in the following instructions.
ATTENTION : Connect and disconnect DC output clips only after setting any charger switches to the “OFF” position and removing the AC cord from the electric outlet. Never allow clips to touch each other.

1. Make sure that the AC power cord is unplugged from the AC outlet and make sure the vehicle’s engine is turned off.
2. Position the AC power cord and DC output cables in such a manner that they cannot be damaged by moving engine parts or the vehicle’s hood or doors.
3. Check the polarity of the battery terminals. The POSITIVE terminal should be marked POSITIVE, POS, + or P. The NEGATIVE terminal should be marked NEGATIVE, NEG, – or N.
4. Determine whether the vehicle has a positive or negative grounded battery (positive or negative cable is connected to the vehicle’s chassis).

WARNING: Moving engine parts can cause serious injury! Stay clear of fan blades, belts, pulleys and other moving engine parts to reduce the risk of serious personal injury. Negative Ground Vehicles (most common, see Figure 5)

1. Connect the POS (red, +) clamp from the battery charger to the POS, ungrounded terminal of the battery.
2. Connect the NEG (black, –) clamp from the battery charger to a heavy gauge metal part of the vehicle chassis or engine block away from the battery. DO NOT connect the NEG charger clamp to the NEG battery terminal, carburetor, fuel lines or sheet metal body parts.
3. Positive Ground Vehicles
4. Connect the NEG (black) charger clamp to the NEG, ungrounded terminal of the battery.
5. Connect the POS (red) charger clamp to a heavy gauge metal part of the vehicle chassis or engine block away from the battery. DO NOT connect the POS (red) charger clamp to the POS battery terminal, carburetor, fuel lines or sheet metal body parts.
6. When disconnecting the charger, turn the switches off, disconnect the AC cord, remove the clip form the vehicle chassis, and then remove the clip from the battery terminal.

Connecting to Batteries Outside a Vehicle

1. Make sure that the AC power cord is unplugged from the AC power source.
2. Check the polarity of the battery terminals (see Figure 6). The POSITIVE terminal should be marked POSITIVE, POS, +, or P. The NEGATIVE terminal should be marked NEGATIVE, NEG, – or N.
3. Attach a battery or booster cable, AT LEAST 24 inches long, that is the same (or larger) wire gauge as the charger cable, to the NEGATIVE terminal of the battery.
4. WARNING: Battery explosion can injure, and cause property damage! To reduce the risk of battery explosion, NEVER connect both battery charger clamps directly to the two posts of a battery.
5. Connect the POS (red) charger clamp to the POS battery terminal. Position yourself and the free end of the cable (attached to the NEG battery terminal) as far away from the battery as the cable will allow. Then, WHILE FACING AWAY FROM THE BATTERY, connect the NEGATIVE charger clamp to the free end of the cable.
6. When disconnecting the charger, turn the switches to off, disconnect the AC cord, and disconnect the charger, always in the reverse sequence of connecting procedure and break the first connection while as far away from the battery as practical.

Charging Mode Operation

ATTENTION: Do not plug the charger power cord into the AC power source or set any of the charger’s controls until told to do so in the following instructions.
ATTENTION: Verify output cable connectors are properly seated and locked in place.
ATTENTION: Connect and disconnect DC output clamps only after setting the power switch to the “OFF” position and unplugging the AC cord from the electric outlet. Never allow clamps to touch each other.
ATTENTION: Do not operate the charger in a closed area or restrict ventilation in any way. Ensure that there are no obstructions to the air flow, so the internal fans can properly cool the unit. Upon checking that your output cables are properly seated and locked into the unit, make a proper battery connection (see Connecting to a Battery Sections as applicable) and plug the AC power cord into an AC receptacle. Then, turn the master power switch located on the back of the unit to ON. The charger is now in Standby Mode. In order to place the unit into Charging Mode, toggle the Mode Selection button until the CHARGE LED is lit. If an ERROR Indicator LED lights, disconnect from the AC power supply immediately and determine the cause of the alarm.

The POLARITY light indicates a reverse polarity error connection, while the ERROR light indicates the detection of a battery fault, such as a shorted connection.

1. Choose a battery type setting. To charge Standard and Maintenance Free Flooded Acid batteries, push the Battery Type button until the “STD” LED is lit. To charge AGM and Spiral Wound batteries, push the Battery Type the button until the “AGM” LED is lit.

2. Choose a battery charging rate. Please see Choosing a Charge Rate section for general details related to choosing a charging rate for your application.

3. Press the START button and the charging indicator LED will light. The charger will automatically commence and complete the charging process. If you press the START button at any point during the charging sequence, the charger will stop charging and return to Standby Mode.
   Note: If the ERROR LED lights, disconnect from AC power immediately and determine the cause of the issue. See Additional Features for a list of conditions that might cause an error.

4. Note: The charger is designed to protect against faults and shorts (see Battery Charger Features). If the battery to be charged has an open circuit voltage of less than 1V, the charger will indicate a fault. If, after unplugging unit, checking connections, and verifying all settings, you determine the problem causing the “fault” condition is battery voltage below 1V, you can override the charger’s protection by holding down the “START” button for 3 seconds.

5. The charger will commence the charging sequence and, assuming these are no other hindrances that caused the fault indication, will complete the charging process and automatically turn off when the battery has reached full charge.

6. When the battery approaches full charge and enters the Completion Phase, the green CHARGING COMPLETE indicator will light and the CHARGING indicator will flash. At this point, if time is critical, the battery can be put into service if it will be used in a charging situation, such as in a vehicle that will be used immediately. To reach a true 100% state of charge, the charger should stay connected until the charger reaches the Rest Phase when only the green CHARGING COMPLETE LED is lit.

7. After charging is complete, press the START button to return the unit to Standby Mode, turn off the Master

Power Switch and unplug the charger from the AC power source. Then, disconnect the charger clamp not connected directly to the battery first, and DO NOT allow the clamp to touch anything. Then, disconnect the charger clamp attached to the battery terminal. (See Connecting To Batteries… at the beginning of this section.) Power Supply Mode Operation
ATTENTION: Do not plug the charger power cord into the AC power source or set any of the charger’s controls until told to do so in the following instructions.
ATTENTION: Verify output cable connectors are properly seated and locked in place.
ATTENTION: Connect and disconnect DC output clamps only after setting the power switch to the “OFF” position and unplugging the AC cord from the electric outlet. Never allow clamps to touch each other.

ATTENTION: Do not operate the charger in a closed area or restrict ventilation in any way. Ensure that there that there are no obstructions to the air flow, so the internal fans can properly cool the unit. Upon checking that your output cables are properly seated and locked into the unit, make a proper battery connection (see Connecting to a Battery in a Vehicle Section) and plug the AC power cord into an AC receptacle. Then, turn the master power switch located on the back of the unit to ON. The charger is now in Standby Mode. In order to place the unit into Power Supply Mode, toggle the Mode Selection button until the SUPPLY LED is lit. If an ERROR Indicator LED lights, disconnect from the AC power supply immediately and determine the cause of
the alarm. The POLARITY light indicates a reverse polarity error connection, while the ERROR light indicates the detection of a battery fault, such as a shorted connection.

NOTE: Make sure that the vehicle battery is in good condition and fully charged. A compromised battery can jeopardize your programming event. The unit will not commence the Power Supply mode if the vehicle battery is below 12.0VDC. Charge the battery first to ensure it is capable of supporting a programming event. Choose the desired system voltage level. Using the UP/DOWN arrows in the Power Supply mode voltage control zone, set the system voltage level on the display to the desired voltage.
Press the START button. The charger will bring the system voltage to the desired level and hold it at that level, providing power as needed (to a maximum of 100A) to the vehicle to maintain the desired level. If you press the START button at any point during the Power Supply sequence, the charger will stop charging and return to Standby Mode. After the Power Supply session is complete, press the START button to return the unit to Standby Mode, turn off the Master Power Switch and unplug the charger from the AC power source. Then, disconnect the charger clamp not connected directly to the battery first, and DO NOT allow the clamp to touch anything. Then, disconnect the charger clamp attached to the battery terminal. (See Connecting To Batteries… at the beginning of this section.)

Charging Amp Settings
Model Number Operating Voltage Charging Rate Power Supply Max Output PL6800 12V 100/40/10A 100A

MAINTENANCE

CAUTION: Make sure the charger is unplugged from AC outlet before performing any cleaning or maintenance.

1. Inspect clamps after each use for any damage that may have occurred. to prevent corrosion. Battery fluid may be neutralized with a solution of water and baking soda.
2. Wipe off any battery fluid that may have come in contact with the clamps to prevent corrosion. Battery fluid may be neutralized with a solution of water and baking soda.
3. Disconnect output cables from unit after each use and protect the terminals. Protect the input cable from damage.
4. Make sure case venting is open and unobstructed allowing the air to flow freely.
5. If needed, the case may be wiped clean with a dry, soft cloth.

Moving and Storage

1. Always disconnect from the AC power source when placing the unit into storage.
2. Store the unit indoors in a clean, dry environment.
3. Always store and transport the unit upright to prevent damage.

TROUBLESHOOTING

No display and the LEDs are not lit.

1. The unit has a low-power mode, pressing any button will exit the low-power mode.
2. Check that the input power cord is plugged in at both the unit and the receptacle.
3. Check that the power switch is turned ON.
4. Check power at receptacles.

The display reads 0.0V.

1. Check that output cables are properly seated and locked.
2. Make sure that the positive clamp is making a good connection to the positive battery terminal.
3. Make sure that the negative clamp is making good connected to a grounded point on the chassis.
4. If you have verified all connections are correct, the problem may be that the battery is severely discharged. In this case you can press and hold the START button for at least 3 seconds, but no more than 10 seconds, to override and start a charge.

Unit unexpectedly and inappropriately reduces output.

1. The unit has thermal protection. In an overheat condition, it will reduce the output power to protect itself.
2. Make sure that the fans are properly working and that there are no obstructions to the air flow. The battery does not accept a charge.
3. Make sure the charger is plugged into a properly functioning AC outlet.
4. After unplugging the unit, check the connection at the battery. Make sure the clamps are making good contact with the battery terminal (or vehicle chassis).
5. Make sure that the output cable connectors are properly seated and locked.
6. Check to see that the battery is capable of being charged – it may be damaged or sulfated.
7. Make sure that you have selected the proper charge voltage for the battery being charged.
8. Make sure you are allowing enough time for charging the battery. See Limited Warranty for further information on obtaining service.

LIMITED WARRANTY

Clore Automotive, L.L.C. warrants that for 1 year from the date of the original retail purchase of the entire unit, it will repair, at no charge for parts and labor, this product if proven defective in material or workmanship. If, after reasonable efforts by Clore Automotive, the product is deemed not repairable, Clore Automotive will, at its option, refund the original purchase price or supply a replacement unit. THE TERMS OF THE CLORE AUTOMOTIVE LIMITED WARRANTY CONSTITUTE THE BUYER’S SOLE AND EXCLUSIVE REMEDY. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THIS EXPRESS WARRANTY. AFTER 1 YEAR FROM DATE OF PURCHASE, ALL RISK OF LOSS FOR WHATEVER REASON SHALL BE PUT UPON THE PURCHASER. CLORE AUTOMOTIVE SHALL NOT BE LIABLE FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES UNDER ANY CIRCUMSTANCES: CLORE AUTOMOTIVE’S LIABILITY, IF ANY, SHALL NEVER EXCEED THE PURCHASE PRICE OF THIS MACHINE REGARDLESS OF WHETHER LIABILITY IS PREDICTED UPON BREACH OF WARRANTY (EXPRESS OR IMPLIED), NEGLIGENCE, STRICT TORT OR ANY OTHER THEORY.

This warranty extends to each person who acquires lawful ownership within 1 year of the original retail purchase but is void if the product has, in Clore Automotive’s sole judgment, been abused, altered, misused or improperly packaged and damaged when returned for repair. This warranty applies to the product only and does not apply to any accessory items included with the product, which are subject to wear from usage; the replacement or repair of these items shall be at the expense of the owner. Some states do not permit the limitation of warranties or the limitation of consequential or incidental damages, so the above disclaimer and limitation may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

TO OBTAIN SERVICE UNDER THIS WARRANTY
Bring or send to the nearest Clore Automotive Authorized Warranty Service Center along with a copy of your purchase receipt, or call Technical Service at 800-328-2921. To locate the nearest Clore Automotive Authorized Warranty Service Center, go to www.cloreautomotive.com. If this product fails within the first 30 days after retail purchase due to a defect in material or workmanship, return it to your place of purchase for an exchange. A valid, dated sales receipt is required to obtain service
under this warranty.

Registering Your Purchase
For the best service and to receive periodic product updates, follow the instructions below to register your purchase:
Please visit: www.cloreregistration.com
Click on the SOLAR logo
Complete the information in the web form and click “submit”

It’s that easy!
For answers to questions concerning use, out-of-warranty service, or warranty/service information on this or other
Clore Automotive products, contact: Clore Automotive Technical Service
800.328.2921 913.310.1050
www.cloreautomotive.com
Model No. PL6800 Part No. 141-610-000

Warning: This product can expose you to chemicals, including Vinyl-Chloride, Styrene, and Acrylonitrile, which are known to the State of California to cause cancer. For more information.Designed and quality assured by Clore Automotive, LLC, Kansas City, MO USA. Made in China to Clore Automotive’s specifications.

References

• Battery Council International Home | Battery Council International
• Home - Clore Automotive
• Clore Automotive Registration
• P65Warnings.ca.gov
• SOLAR Portable Battery Chargers - Clore Automotive

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