Projecta PC800 Pro-Charge Battery Charger FAQ & Troubleshooting Guide

Projecta PC800 Pro-Charge Battery Charger FAQ & Troubleshooting Guide

Projecta PC800 Pro-Charge Battery Charger FAQ & Troubleshooting Guide


Applies To

Projecta PC800
Pro-Charge Battery Charger
12V 8A 6 Stage Switchmode Battery Charger


Overview

The Projecta PC800 is a 12V 8A Pro-Charge automatic battery charger designed for charging and maintaining 12V lead acid batteries.

It uses a 6-stage automatic charging process to help charge, test and maintain the battery. Once charging is complete, the charger moves into float mode and can remain connected to maintain the battery.

The PC800 is suitable for most 12V automotive, marine and deep-cycle lead acid batteries, including GEL, AGM, WET CELL and Calcium batteries.


Key Features

The PC800 includes:

6-stage automatic charging
Normal and Calcium charge modes
Manual Rejuvenation mode
Adjustable charge rate
Switchmode technology
Spark-free protection
Reverse polarity protection
Moulded battery clips
Side mounting wings
Cooling vents
Float maintenance charging


Battery Compatibility

What batteries can the PC800 charge?

The PC800 is designed for 12V lead acid batteries only.

It is suitable for:

GEL batteries
AGM batteries
WET CELL batteries
Calcium batteries
Automotive batteries
Marine batteries
Deep-cycle batteries

Can the PC800 charge lithium batteries?

No.
The uploaded manual states the PC800 is for 12V lead acid batteries only.

Do not use the PC800 to charge lithium batteries.

What battery size is suitable for the PC800?

Recommended battery range:

Deep cycle: 14–160Ah
Automotive: 80–1000CCA
Marine: 110–1300MCA

Can the PC800 charge 6V or 24V batteries?

No.
The PC800 is a 12V charger only.


Charging Operation

How does the PC800 charge the battery?

The PC800 uses a 6-stage charging process:

Rejuvenation — Manually initiated 24-hour high frequency charge to help break down sulphation.
Soft Start — Gently introduces power to the battery.
Bulk — Charges at maximum current up to the set voltage.
Absorption — Charges the battery to 100% using controlled voltage.
Battery Test — Checks whether the battery has accepted charge.
Float — Maintains the battery at full charge without overcharging.

In Calcium mode, the charger also uses an Equalisation stage to support calcium batteries.

Can the PC800 be left connected?

Yes.
When the battery is fully charged, the green Float / Full LED illuminates and the charger moves into float mode.

The charger can remain connected to maintain the battery.


Charge Modes

What is Normal mode?

Normal mode is used for most 12V lead acid batteries, including:

GEL
AGM
WET

What is Calcium mode?

Calcium mode adjusts the charge profile for calcium batteries.

It includes an Equalisation stage that can raise the battery voltage to support recovery of deeply discharged calcium batteries.

What is Rejuvenation mode?

Rejuvenation mode is manually started and runs a high frequency intermittent charge for up to 24 hours.

It may help restore tired or sulphated batteries.

To start Rejuvenation mode, hold the Battery Type button for approximately 3 seconds until the Rejuvenation LED starts flashing.

To stop Rejuvenation mode manually, hold the Battery Type button again for approximately 3 seconds.


Charge Rate Selection

What charge rates are available on the PC800?

The PC800 supports:

2A
4A
8A

Select the charge rate based on the battery size.

Recommended guide:

2A: 14–40Ah deep cycle / 80–240CCA automotive / 110–330MCA marine
4A: 30–80Ah deep cycle / 180–480CCA automotive / 250–650MCA marine
8A: 60–160Ah deep cycle / 360–1000CCA automotive / 500–1300MCA marine


How to Use

Before charging

Before using the PC800:

Read the instruction manual.
Use indoors only.
Do not expose the charger to rain.
Charge in a well-ventilated area.
Keep flames, sparks and smoking materials away from the battery.
Do not charge a frozen battery.
Do not charge a damaged or non-rechargeable battery.
Turn off vehicle accessories before charging.
Disconnect the 240V mains supply before making or breaking battery connections.


Battery out of vehicle

  1. Connect the red lead to the positive + battery post.
  2. Connect the black lead to the negative – battery post.
  3. Connect the charger to 240V mains power.
  4. Select the correct charge rate.
  5. Select Normal, Calcium or Rejuvenation mode if required.
  6. Allow the charger to complete the automatic charge cycle.

Battery in vehicle — negative earth

Most vehicles are negative earth.

  1. Connect the red lead to the positive + battery terminal.
  2. Connect the black lead to the vehicle chassis away from fuel lines or moving parts.
  3. Connect the charger to 240V mains power.
  4. Select the correct charge rate and battery type.
  5. Allow the charger to complete the charge cycle.

Battery in vehicle — positive earth

  1. Connect the black lead to the negative – battery terminal.
  2. Connect the red lead to the vehicle chassis away from fuel lines or moving parts.
  3. Connect the charger to 240V mains power.
  4. Select the correct charge rate and battery type.
  5. Allow the charger to complete the charge cycle.

Permanent Hard Wiring

Can the PC800 be hard wired to the battery?

Yes.
The PC800 can be hard wired to the battery for permanent installations.

Required fuse rating:

PC800: 10A fuse

Connection:

  1. Cut off the supplied battery clips, leaving enough cable to reach the battery terminals.
  2. Do not extend the DC leads, as voltage drop may cause incorrect charging.
  3. Fit a ring terminal to the black negative – wire.
  4. Connect an inline fuse to the red positive + wire.
  5. Connect a ring terminal to the other end of the inline fuse.
  6. Connect the red lead with inline fuse to the positive + battery post.
  7. Connect the black lead to the negative – battery post.
  8. Fit the correctly rated fuse.

Any modification to the 240V mains lead must be carried out by a qualified person.


LED Indicators

How do I know what stage the charger is in?

The PC800 uses coloured LEDs to show charging stage.

Bulk blue LED — Soft Start, Bulk, Absorption and Equalisation stages
Full green LED flashing — Analysis stage
Full green LED solid — Float / fully charged
Rejuvenation amber LED flashing — Rejuvenation mode active
Fault red LED — Fault condition present


Common Troubleshooting

The PC800 will not start charging. What should I check?

Check the following:

Battery voltage is above 3.0V.
Battery clamps are connected correctly.
Red clamp is connected to positive +.
Black clamp is connected to negative – or correct chassis earth.
The 240V mains outlet is switched ON.
The correct battery type is selected.
The battery is not frozen, damaged or faulty.

The PC800 is designed to start charging from 3.0V. If the battery voltage is lower than 3.0V, the charger may not start.


The battery is very flat and the charger will not start. What can be done?

If the battery is below 3.0V, the charger may not detect it.

The manual advises that booster cables can be used between two batteries to provide more than 3.0V to the battery being charged. Once the charger starts charging, the booster cables can be removed.

This should only be done by a competent person and only if the battery is safe to charge.


Can I use the PC800 as a power supply?

No.
The PC800 is designed to supply power only when correctly connected to a battery.

This spark-free safety feature prevents the charger from being used as a standalone power supply.


Why does Calcium mode take so long?

Calcium mode includes an Equalisation stage.

This stage uses constant current up to 16V and can take up to 12 hours. This is normal for calcium battery recovery.


The battery charges but goes flat again. What should I check?

Possible causes include:

Sulphated battery
Faulty cell
Battery at end of life
Parasitic drain in the vehicle
Load left connected during charging
Battery too large for selected charge rate

Load-test the battery before replacing the charger.


Fault Conditions

Battery problem detected

Possible cause:

Battery may be sulphated, deeply discharged or faulty.

Recommended action:

Initiate Rejuvenation mode. If the fault returns, the battery may need to be replaced.

Short circuit or reverse connection

Possible cause:

Clips are touching each other or connected incorrectly.

Recommended action:

Check the clips are not touching and confirm correct polarity.

Bulk charging timeout

Possible cause:

Bulk charging has stopped after 24 hours.

Recommended action:

Battery may be faulty or too large for the selected charge rate.

Over temperature

Possible cause:

The charger is too hot or airflow is restricted.

Recommended action:

Move the charger to a cooler location and check that the fan and vents are not blocked.

Soft Start timeout

Possible cause:

Battery voltage did not rise as expected.

Recommended action:

Check the battery condition and remove any load from the battery.


Specifications

Part number: PC800
Type: 6 stage
Input: 240VAC, 50Hz
Input power: 240W
Output voltage: 12V
Output current: 2A / 4A / 8A
Minimum start voltage: 3.0V
Back drain: 1mA
Normal bulk voltage: 14.4V
Calcium bulk voltage: 14.7V
Float voltage: 13.7V
Deep cycle range: 14–160Ah
Automotive range: 80–1000CCA
Marine range: 110–1300MCA
Battery types: GEL, AGM, WET CELL and Calcium
Size: 216 x 118 x 66mm
Weight: 1.0kg


Safety Warnings

Use indoors only.
Do not expose the charger to rain.
Do not attempt to charge non-rechargeable batteries.
Never charge a frozen battery.
Use in a well-ventilated area.
Keep sparks and flames away from the battery.
Disconnect mains power before connecting or disconnecting battery leads.
Do not use the charger if the AC cord is damaged.
Do not allow children to use or play with the charger.
The charger must be plugged into an earthed socket-outlet.


When to Escalate

Escalate the case if:

The charger repeatedly shows fault after polarity and battery condition are confirmed.
The battery is swollen, leaking, frozen or physically damaged.
The charger case, AC cord or output leads are damaged.
The customer reports overheating, smoke, burning smell or sparking.
The charger trips mains power.
The fan is not operating when required.
The unit behaviour does not match the manual.
Warranty assessment is required.