Thunderbolt 63585 Original instruction manual

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Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference. 17g
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright© 2017 by Harbor Freight Tools®. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Tools required for assem bly and service may not be included.
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Safety ......................................................... 2
Specifications ............................................. 5
Setup .......................................................... 5
Operation .................................................... 9
Maintenance .............................................. 12
Parts List and Diagram .............................. 13
Warranty .................................................... 16
U@;ECEV%?QDWRG?%@EX%X6<CECACRE?
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
CDSR;A@EA%?@<6AQ%CE?A;FTACRE?
;*,9%,77%#,2*$>%),(8"83#%,89%,77%"8#$('4$"&8#1%%
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
?,Y*%,77%),(8"83#%,89%"8#$('4$"&8#%2&(%2'$'(*%(*2*(*84*1
;6@X%@GG%CE?A;FTACRE?
C8#$,77,$"&8%S(*4,'$"&8#
1. 6Z*(4"#*%#/*4",7%4,'$"&8%"2%)&(["83%&8%(&&2%
&(%,8&$.*(%."3.%7&4,$"&81%%Keep proper footing
and balance at all times. Follow ladder supplier’s
precautions whenever working near or on a ladder.
2. C8#$,77%,77%#*8#"$"Y*%*7*4$("4,7%4&5/&8*8$#%
\"847'9"83%)"("83%4&88*4$"&8#I%(*3'7,$&(I%
,89%+,$$*(>]%"8#"9*%,%)*,$.*(/(&&2%
*847&#'(*%$&%/(*Y*8$%*7*4$("4%#.&4[1
3. X&%8&$%)"(*%5'7$"/7*%/,8*7#%"8%#*("*#1%If you
need to connect two or more solar panels together,
this work must be done by a qualified electrician
unless they are connected through a regulator.
4. This solar panel kit is not designed for tie-in to a
grid. Only a licensed electrician and a licensed
building contractor can safely design and implement
a grid tie-in system. Any grid tie-in system must
meet all applicable building and electrical codes,
and must meet standards established by the area
power company. Improper grid tie-in can result
in electrocution, fire, and other serious personal
injury and property damage. An incorrectly installed
grid tie-in system can cause feedback voltage,
resulting in electrocution of electrical utility workers.
5. X&%8&$%#$,89%&8%&(%&$.*()"#*%
,//7>%/(*##'(*%$&%/,8*71

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6. B,897*%#&7,(%/,8*7%)"$.%4,(*I%
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8. C8#$,77%4&5/&8*8$#%)"$.%*8&'3.%
#/,4*%$&%,77&)%/(&/*(%4&&7"831
9. A."#%/(&9'4$%5,>%&44,#"&8,77>%/(&9'4*%
5&(*%4'((*8$%,890&(%Y&7$,3*%$.,8%"$#%(,$*9%
&'$/'$1%%C84(*,#*%&'$/'$%(,$"83#%+>%^N_%).*8%
9*$*(5"8"83%4&5/&8*8$%(*H'"(*9%Y&7$,3*%
,89%,5/*(,3*%(,$"83#1 Refer to Section
690-8 of the National Electrical Code for an
additional multiplying factor of 125 percent
(80 percent derating) which may apply.
10. Panel must be connected using UL listed outdoor
rated wire of the correct thickness (gauge) for the
amperage rating and length (see warning number
9 also). Follow the guidelines in the chart below:
T'((*8$%
"8%@5/#%
D,Z"5'5%G*83$.
N`% Ja`% JN` ^a`% ^N`
0-5 18
6-7 18 16
8 18 16
10
18
16
11-12 16 14
15 14 12
18
18 1620 14 12 10
22-24 12
30 16 14 10
40 12 10 8
50 14
100 12 10 6 4
150 10 84 2
200 8 6
D"8"5'5%U"(*%V,'3*
11. Install an appropriate charge controller/regulator
to regulate output and prevent damage. Do not
attach panel to battery or power grid without proper
regulator, inverter, and/or charge controller.
12. Install and use according to applicable
National Electrical Code (NEC) standards.
13. This panel is not rated for use as fire-resistant
roofing. If installing on a roof, install only over a fire
resistant roof covering rated for the application.
14. Verify that installation surface has no hidden
utility lines before drilling or driving screws.
15. Install only according to these instructions.
Improper installation can create hazards.
16. Handle panel with care. Glass may break or a
sharp edge may be exposed during movement.
17. Keep installation area clean and well lit.
18. Install out of reach of children.
19. Keep bystanders out of the area during installation.
20. Do not install when tired or when under
the influence of drugs or medication.
21. Use in 12 VDC systems only.
22. The warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
that may occur. It must be understood by the
operator that common sense and caution are
factors which cannot be built into this product,
but must be supplied by the operator.
W,$$*(>%S(*4,'$"&8#
1. U*,(%#/7,#.K(*#"#$,8$%@E?CK,//(&Y*9%
#,2*$>%3&337*#%,89%*7*4$("4,77>%"8#'7,$*9%
37&Y*#%)."7*%)&(["83%8*,(%+,$$*("*#1
2. F#*%,8%,//(&/(",$*%4.,(3*%4&8$(&77*(%
).*8*Y*(%4&88*4$*9%$&%+,$$*(>1
3. Charge, store, and maintain batteries
according to supplier’s instructions.
C8#$,77,$"&8%S(*4,'$"&8#%\4&8$b9]

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b. T&Y*(%,77%#&7,(%/,8*7#%)"$.%,8%&/,H'*%
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3. X&%8&$%#$,89%&8%&(%&$.*()"#*%
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4. Do not allow children to play with or
near this or electrical components.
5. Inspect at least monthly; do not use if damaged,
parts are loose, water is found inside the
housing, electrical insulation is cracked or
damaged, or connections are loose.
6. Maintain product labels and nameplates.
These carry important safety information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
%?@!6%AB6?6%CE?A;FTACRE?1

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?/*4"2"4,$"&8#
Rated Output 18 VDC / 25 W (per solar panel)
Open Circuit Voltage 23.6 OCV
E&$*- Performance will vary depending on temperature, brightness and time of sun exposure. Summer
production will be higher than in the winter. Bright sunny days will generate higher output than cloudy days.
?*$%F/%C8#$('4$"&8#
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"847'9"83%,77%$*Z$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1
AR%S;6!6EA%?6;CRF?%CEcF;Q%<;RD%@TTCX6EA@G%RS6;@ACRE-%
D,[*%#'(*%$.,$%$.*%S&)*(%?)"$4.0A("33*(%"#%"8%$.*%&22K/&#"$"&8%,89%'8/7'3%$.*%$&&7%
2(&5%"$#%*7*4$("4,7%&'$7*$%+*2&(*%/*(2&(5"83%,8>%/(&4*9'(*%"8%$."#%#*4$"&81
E&$*- For additional information regarding the parts listed in the following pages,
refer to the Assembly Diagram near the end of this manual.
C8#$,77,$"&8
G&4,$"&8
1. Locate the Solar Panels (12) where they will
receive full, unobstructed sunlight, especially during
midday. Nearby trees or tall plants will drop debris,
requiring the panels to be cleaned more frequently.
2. The setup location for the Solar Panel Kit must
be inaccessible to children to prevent electric
shock. Build a childproof enclosure if needed.
3. Install the charge controller/regulator and batteries
in a weatherproof enclosure with proper ventilation.
D&'8$"83
1. Select a mounting location for the Solar Panel
Kit. The Solar Panels should face the Sun, and
not be blocked by shadows. The location should
allow the Panels to be protected from accidental
damage. The location should be flat, stable and
able to support the weight of the Solar Panel
Kit’s accessories. Before assembly, be sure
that all accessory cables reach their connection
points without placing any stress on the wiring.
2. Angle face of Solar Panel Frame toward true
south1 according to chart that follows:
G,$"$'9*% ?&7,(%S,8*7%@837*%
0-4° 10°
5-20° Latitude + 5°
21-45° Latitude + 10°
46-64° Latitude + 15°
65° or more 80°
1 Angle towards true north if installed
in southern hemisphere.

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@##*5+7>
1. Place two panels side-by-side on a flat surface.
X&%8&$%9(&/%$.*%/,8*7#%&(%,77&)%
,8>&8*%$&%7*,8%&(%#$*/%&8%$.*51
2. Insert Screws (6) into the innermost mounting
holes of first two solar panels. See Figure A.
?4(*)%\M]
D&'8$"83%B&7*#
<"3'(*%@
3. Use Wing Nuts (9) to fasten the
Connection Brace (7) onto the top back
ends of solar panels. See Figure B.
U"83%E'$%\P]
T&88*4$"&8%
W(,4*%\O]
<"3'(*%W
4. Repeat for the bottom ends of panels.
Insert Screws into mounting holes along the
bottom end and fasten Connection Brace onto
the back using Wing Nuts. See Figure C.
?4(*)#
<"3'(*%T
5. Repeat Steps 1-4 for the other two
solar panels. See Figure D.
<"3'(*%X
6. The Mounting Stands on each panel come
pre-assembled. After panel assembly, stand
panels upright and pull each Mounting Stand
out to locked position. See Figure E.
G&4[*9%S&#"$"&8
<"3'(*%6

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7. Connect end of lead wires coming from the Solar
Panels (1) to the Splitter Cable (2). See Figure F.
?/7"$$*(%
T,+7*#%\^]
<"3'(*%<
8. Connect the wires of the Battery
Clamps to the battery terminals on the
bottom of the Charge Controller.
9. Attach the Battery Clamps to the battery’s
terminals. (Battery not included.)
U@;ECEVd%%Connect red connector to positive (+).
Connect black connector to negative (-). Unit will not
function with reverse connection. See Figure G.
W,$$*(>%A*(5"8,7#
T.,(3*%
T&8$(&77*(%\e]%
<"3'(*%V
10. Connect Splitter Cable to the DC connector
cable. Plug DC cable into Solar Input jack
on the Controller. See Figure H.
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C8/'$
?/7"$$*(%T,+7*%\^]
XT%T&88*4$&(
T,+7*%\L]
<"3'(*%B

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U"("83
E&$*- Only a licensed electrician and a licensed building
contractor can safely design and implement a grid
tie-in system. Any grid tie-in system must meet all
applicable building and electrical codes, and must meet
standards established by the area power company.
1. Run wires from panels, through weatherproof
grommets and into enclosure where power
inverter is located. Use wires of the proper
size and rating and use twist connectors
(not included) to connect wires.
2. Connect battery to power inverter according
to inverter’s instructions. U@;ECEVd Inverter
must be properly rated and designed for this
type of connection and power supply.
3. Secure all connections using terminals, or solder
all wire splices to ensure good connections.
4. Weatherproof all connections and route the wire in
a way that it will not be torn loose from the panel.

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%R/*(,$"83%C8#$('4$"&8#
;*,9%$.*%6EAC;6%CDSR;A@EA%?@<6AQ%CE<R;D@ACRE%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%5,8',7%
"847'9"83%,77%$*Z$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1
%%E&$*-%%Performance of the Solar Panels will vary dependent on site location, angle
of the panels in relation to the arc of the sun, and available sunlight.
T.,(3*%T&8$(&77*(%?*$$"83#
ERACT6- TREA;RGG6;%DF?A%W6%TREE6TA6X%AR%@%TB@;V6X%
J^!%G6@XK@TCX%W@AA6;Q%AR%SRU6;%AB6%XC?SG@Q1
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<"3'(*%C%
1. Press the Load Button to toggle
the 12V output on/off.
2. Press the Display Button to cycle the Display
between the 5 different settings shown below.
3. Each of the below settings can be set
manually by the user. To do this:
a. Press and hold the Display Button
while the setting is shown until the
voltage display starts blinking.
b. While the Display is blinking:
• Press the Display Button to increase setting.
• Press the Load Button to decrease setting.
c. When setting is complete, press and
hold the Display Button until the voltage
Display stops blinking. The set value
will be saved by the controller.
d. Press Display button again to
cycle to next setting.
E&(5,7
Target charging
voltage. Can also
be used to access
advanced settings.
W&&#$
Maximum
charging output
voltage to finish
charging battery.
<7&,$
Maintenance
charge voltage.
G&)
Battery voltage is
too low to charge
without damaging
battery. Battery will
need to be charged
separately first,
but may already
be ruined from
over-discharge.
;*4&Y*(>
Minimum battery
voltage where
normal charging
can resume.

Page 10 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63585
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E&$*- User can also cycle through and set
the special parameters for Battery Type,
Temperature Ratio, and Output Duration.
4. When Digital Voltage Meter is in E&(5,7 mode,
press and hold the Display button until Battery
Type display appears, as shown below.
W,$$*(>%A>/*
1. Press and hold Display button until Battery
Type display starts blinking, then press Display
button to toggle down through each battery
type. Use Load button to toggle back up.
E&$*- The different battery types are User Mode
(USr), Sealed, (SLd), Flooded (FLd), and Gel (GEL).
2. When desired Battery Type is found, press and
hold Display button until display stops blinking.
The set value will be saved by the controller.
3. Press Display button once to cycle to
Temperature Ratio display, as shown below.
A*5/*(,$'(*%;,$"&
E&$*- A reading of -4 indicates -4mV/cell/°C.
4. Press and hold Display button until display starts
blinking, then press either Display button to
increase setting or Load button to decrease.
5. When finished, press and hold Display
button until display stops blinking. The set
value will be saved by the controller.
6. Press Display button once to cycle to Ouput
Duration display, as shown below.
R'$/'$%X'(,$"&8
E&$*- 15h indicates 15 hours before the
output automatically shuts off.
7. Press and hold Display button until display starts
blinking, then press either Display button to
increase setting or Load button to decrease.
8. When finished, press and hold Display
button until display stops blinking. The set
value will be saved by the controller.
9. Let the controller sit for about five seconds
and it will return back to E&(5,7 mode.
E&$*- The user may see the following Error
Codes when voltage limits are reached:
E11: Low-voltage protection; battery voltage
is below 10.5-10.8V. Controller will shut off
and enter low-voltage protection state.
E12: High-voltage protection; battery voltage
is above 16.1V. Controller will stop input
and enter overvoltage protection state.
E13: Overload protection; indicates the
occurence of overcurrent. Controller will stop
output and enter overload protection state.
E14: System short-circuit protection.

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F#"83%J^%!&7$%G"3.$#%,89%@44*##&("*#
ERACT6- TREA;RGG6;%DF?A%W6%TREE6TA6X%AR%@%TB@;V6X%%
J^!%G6@XK@TCX%W@AA6;Q%AR%SRU6;%AB6%XC?SG@Q1
1. Press the Load Button to toggle
the 12V output on/off.
2. Plug the end of the LED Light’s cable into
one of the 12V DC outlets on the Charge
Controller as shown in Figure J.
J^!%XT%R'$7*$#
F?W%
R'$/'$#
J^!%@//7",84*%A*(5"8,7#
?&7,(%S,8*7%
A*(5"8,7#
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3. Connect a DC adapter cable (not
included) to the appliance.
4. Insert the plug on the other end of the cable into one
of the 12V DC Outlets on the Charge Controller.
5. Activate your appliance.
ERACT6- Only use one appliance at a
time with this Charge Controller.
6. When finished, unplug the DC adapter cable
(not included) from the Charge Controller and
then unplug the cable from the appliance.
7. To charge a cell phone or other small electronic
item, plug the item’s power cord into the USB
Port on the front of the Charge Controller.
E&$*-%?&7,(%/,8*7#I%7"3.$#I%,89%,44*##&("*#%
4,8%+*%.,(9)"(*9%&8$&%$.*%$*(5"8,7#%&8%$.*%
+&$$&5%&2%$.*%4.,(3*%4&8$(&77*(%"8#$*,9%&2%
'#"83%$.*%"847'9*9%/7'3#1%%?**%<"3'(*%c1%

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D,"8$*8,84*%,89%?*(Y"4"83
S(&4*9'(*#%8&$%#/*4"2"4,77>%*Z/7,"8*9%"8%$."#%5,8',7%%
5'#$%+*%/*(2&(5*9%&87>%+>%,%H',7"2"*9%$*4.8"4",81
AR%S;6!6EA%?6;CRF?%CEcF;Q%<;RD%6G6TA;CT%?BRTf-%%
W*2&(*%#*(Y"4*I%5,"8$*8,84*%&(%47*,8"83-
a. X(>%#&7,(%/,8*7#%,89%&'$9&&(%)"("83%$.&(&'3.7>%)."7*%)*,("83%*7*4$("4,77>%"8#'7,$*9%37&Y*#1
b. T&Y*(%#&7,(%/,8*7#%)"$.%,8%&/,H'*%4&Y*(1
c. X"#4&88*4$%,77%#&7,(%/,8*7#%,89%+,$$*("*#1
AR%S;6!6EA%?6;CRF?%CEcF;Q%<;RD%6G6TA;CT%?BRTf%R;%TFA?-%%%
X&%8&$%'#*%9,5,3*9%#&7,(%/,8*71%%%
C2%)"("83%"8#'7,$"&8%"#%9,5,3*9%&(%)*,$.*(*9I%37,##%"#%4(,4[*9I%&(%.&'#"83%"#%&/*8*9I%.,Y*%$.*%
/(&+7*5%4&((*4$*9%+*2&(*%2'($.*(%'#*1
E&$*- It is normal to see up to 20% degradation in amorphous silicon solar panel
performance within the first 6 months before the amorphous coating stabilizes.
T7*,8"83I%D,"8$*8,84*I%,89%G'+("4,$"&8
Clean and inspect the Solar Kit system MONTHLY,
or more frequently to maintain peak efficiency.
1. Wear electrically insulated gloves and
ANSI-approved safety goggles. Dry solar
panels and outdoor wiring thoroughly.
2. Cover solar panels with opaque cover.
3. Disconnect all solar panels and batteries.
4. Clean solar panels one at a time with mild, non-
abrasive cleanser and soft cloth and paper towels.
Do not clean with brushes or abrasive cleaners.
5. Inspect general condition of Solar Kit system
(panels, batteries, controllers, and mounting).
Check for loose hardware, wiring insulation damage
or weathering, cracked glass, open housing, cracked
or broken parts, loose or corroded contacts, and any
other condition that may affect its safe operation.
6. Maintain batteries according to
supplier’s instructions.
@9='#$5*8$
To increase efficiency:
1. C8%$.*%U"8$*(I increase the panels’ angle by 10°.
2. C8%$.*%?'55*(I decrease the angle by up to 10°.
3. C8%?/("83%,89%<,77I keep the angle recommended on page 5.

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THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

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1 Solar Panel 4
2 4-in-1 Splitter Cable 1
3 Charge Controller 1
4 Battery Clamp Cable 1
5 LED Light 2
S,($ X*#4("/$"&8 g$>
6 Screw 6
7 Connection Brace 6
8 DC Connector & J-plug 1
9 Wing Nut 6
1
2
3
4
5
6
8
7
9

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E&$*- If product has no serial number, record
month and year of purchase instead.
E&$*- Some parts are listed and shown for
illustration purposes only, and are not available
individually as replacement parts.

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Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries
to persons or property, or for incidental, contingent, special or consequential damages arising from the use of
our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.
If our inspection verifies the defect, we will either repair or replace the product at our election or we may
elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will
return repaired products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
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