Sealey SMC04 User manual

1. SAFETY INSTRUCTIONS
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and
properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS, AND
CAUTIONS. USE THIS PRODUCT CORRECTLY, AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO
MAY CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY.
1.1 ELECTRICAL SAFETY
WARNING! It is the responsibility of the owner and the
operator to read, understand and comply with the
following: You must check all electrical products,
before use, to ensure that they are safe. You must
inspect power cables, plugs, sockets and any other
connectors for wear or damage. You must ensure that
the risk of electric shock is minimised by the installation of
appropriate safety devices. A Residual Current Circuit
Breaker (RCCB) should be incorporated in the main
distribution board. We also recommend that a
Residual Current Device (RCD) is used. It is particularly
important to use an RCD with portable products that
are plugged into a supply which is not protected by an
RCCB. If in any doubt consult a qualified electrician.
You may obtain a Residual Current Device by
contacting your Sealey dealer. You must also read and
understand the following instructions concerning
electrical safety.
1.1.1 The Electricity at Work Act 1989 requires that all
portable electrical appliances, if used on business premises,
are tested by a qualified electrician, using a Portable
Appliance Tester (PAT), at least once a year.
1.1.2 The Health & Safety at Work Act 1974 makes
owners of electrical appliances responsible for the safe
condition of those appliances and the safety of the
appliance operators. If in any doubt about electrical
safety, contact a qualified electrician.
1.1.3 Ensure that the insulation on all cables and on the
appliance is safe before connecting it to the power
supply. See 1.1.1 and 1.1.2 and use a Portable
Appliance Tester.
1.1.4 Ensure that cables are always protected against short
circuit and overload.
1.1.5 Regularly inspect power supply cables and plugs for
wear or damage and check all connections to ensure
that none are loose.
1.1.6 Important: Ensure that the voltage marked on the
appliance matches the power supply to be used and
that the plug is fitted with the correct fuse - see fuse
rating to right.
1.1.7 DO NOT pull or carry the appliance by the power cable.
1.1.8 DO NOT pull the plug from the socket by the cable.
1.1.9 DO NOT use worn or damaged cables, plugs or
connectors. Immediately have any faulty item repaired
or replaced by a qualified electrician. When a BS 1363/A
UK 3 pin plug is damaged, cut the cable just above the
plug and dispose of the plug safely. Fit a new plug
according to the following instructions (UK only).
a) Connect the GREEN/YELLOW earth wire to the
earth terminal ‘E’.
b) Connect the BROWN live wire to the live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral
terminal ‘N’.
d) After wiring, check that there are no bare wires,
all wires have been correctly connected, the cable
outer insulation extends beyond the cable restraint
and that the restraint is tight.
Double insulated products, which are always marked
with this symbol , are fitted with live (brown) and
neutral (blue) wires only. To rewire, connect the wires
as indicated below. DO NOT connect either wire to the
earth terminal.
1.1.10 If an extension reel is used it should be fully unwound
before connection. A reel with an RCD fitted is
preferred since any appliance plugged into it will be
protected. The cable core section is important and
should be at least 1.5mm², but to be absolutely sure
that the capacity of the reel is suitable for this product
and for others which may be used in the other output
sockets, we recommend the use of 2.5mm² section
cable.
1.2 GENERAL SAFETY
 WARNING!DO NOT USE ON ANY OTHER BATTERIES
APART FROM SEALED LEAD ACID BATTERIES.
 WARNING!Disconnect the charger from the mains
power before servicing or performing any maintenance.
Disconnect the charger from the mains power before
connecting to, or disconnecting from, the battery.
 Maintain the charger in good condition (use an
authorised service agent only).
 WARNING!Charger has components such as a switch
which may cause sparks or arcs. When using the
charger in a garage or workshop, make sure it is in a
safe location.
Keep the charger clean for best and safest performance.
WARNING! Ensure there are no sources of ignition near
the work area i.e. naked flames, cigarettes, flame
heaters etc as the charging process produces
explosive gases.
WARNING! Ensure the working area is well ventilated
as the gases produced are explosive.
Locate the charger in a suitable work area. Keep area
clean and tidy and free from unrelated materials, and
ensure there is adequate lighting.
Wear approved safety eye protection (standard
spectacles are not adequate).
Remove ill fitting clothing. Remove ties, watches, rings,
and other loose jewellery, and contain long hair.
Read vehicle manufacturer’s instructions manual to
check for any specific battery charging information.
Disconnect the battery from the vehicle and move it to
a safe, dry level area for charging. If the battery cannot
be removed from the vehicle refer to manufacturer’s
hand book.
Clean the charger clamps and battery terminals to
remove any oxidation.
Ensure the correct clamp polarity is observed when
connecting to the battery. Positive is indicated by (+)
and is Red, negative is indicated by (-) and is black.
Keep children and unauthorised persons away from the
working area.
DO NOT pull or carry the charger by its power supply
lead. Products must not be pulled or carried by their
output cables.
DO NOT pull power plugs from sockets by the power
cable.
Original Language Version SMC04 Issue: 1 - 31/10/13
INSTRUCTIONS FOR:
COMPACT AUTO INTELLIGENT BATTERY
CHARGER-9-CYCLE 12V
MODEL NO: SMC04
©Jack Sealey Limited

DO NOT use worn or damage leads, plugs or
connections. Immediately replace or repair by qualified
persons. A U.K. 3 pin plug with ASTA/BS approval is
fitted. In case of damage, cut off and fit a new plug
according to 1.1.9.
DO NOT attempt to charge a non-rechargeable battery.
DO NOT use the charger for any purpose other than
that for which it is designed.
DO NOT allow the charger terminal clamps to touch
each other when the power is on. Remember that
gases are produced which may ignite if sparks occur.
DO NOT place the charger inside the vehicle.
Remove the battery to a safe distance for charging.
DO NOT get the charger wet or use in damp or wet
locations or areas where there is condensation.
DO NOT operate the charger if damaged.
DO NOT charge the battery with the engine running.
DO NOT attempt to modify or open the charger.
When not in use unplug from the mains power supply
and store in a safe, dry, secure area.
WARNING!Be vigilant and cautious during the
operation of battery charging as the electrolyte is
highly corrosive and any gases emitted are explosive.
DO NOT allow untrained persons to operate the charger.
This appliance is not intended for use by persons
with reduced physical, sensory or mental capabilities, or
lack of experience and knowledge, unless they have
been given instruction concerning the use of the
appliance and are supervised by a person responsible
for their safety.
Keep children and unauthorised persons away from the
working area. Children must not use the charger and should
be constantly supervised to ensure they do not play with the
charger.
2. INTRODUCTION
SPECIFICATION
MODEL NO: SMC04
Input Voltage 230V
Output Voltage 12V
Type 9-Cycle
Input Current 0.6A
Efciency >80%
Battery Types SLA, WET, AGM, VRLA, Lead Calcium
Charging Current 8A
Back Current Drain <1Ah/month
Ambient Temperature -20°C to +50°C
Dimensions (LxWxH) 210 x 94 x 58mm
Housing protection IP44
Weight: 1.07 kg
Fully automatic 9-cycle switch mode charger and maintainer
designed for charging a variety of batteries: SLA, WET, AGM,
VRLA and Lead Calcium. You know exactly how the charger is
performing; the LED display indicates charging or
maintenance phase. Charger will recover slightly sulphated
batteries and may rescue drained batteries. Supplied with
multi-fit charger cables featuring crocodile clips, eyelets,
vehicle accessory socket, plug and hard-wired terminals
incorporating a water tight plug and socket for permanent
installation. For motorcycles and cars.
3. CONNECTION TO BATTERY
Original Language Version SMC04 Issue: 1 - 31/10/13
©Jack Sealey Limited
NOTE: THE CHARGER SHOULD BE CONNECTED TO
THE BATTERY OR THE VEHICLE ACCESSORY SOCKET,
BEFORE CONNECTING TO THE MAINS SUPPLY.
3.1 The output cable from the charger terminates in a socket
into which three alternative leads can be connected. (see
Fig.1)
3.1.1 One lead set (A) has two colour coded battery clamps which
can be quickly attached to and detached from the battery
posts. The other end of the cable terminates with a
plug for connection to the charger lead socket.
3.1.2 The second lead (B) can be connected to the vehicle via
the vehicle accessory socket. The other end of the cable
terminates with a plug for connection to the charger lead
socket.
3.1.3 The third lead (C) is for semi permanent connection to the
battery via eyelets.The other end of the cable terminates
with a plug for connection to the charger lead socket.
Wear safety eye protection and protective clothing.
Avoid touching eyes while working near battery.
Have fresh water and soap nearby in case battery acid
contacts skin, clothing or eyes.
Wash immediately with soap and water if battery acid
contacts skin or clothing. If acid enters eye, flush eye
immediately with cool, clean running water for at least
15 minutes and seek immediate medical attention.
Remove personal metallic items such as rings,
bracelets, necklaces and watches. A lead acid
battery can produce a short-circuit current high enough
to weld a ring or similar to metal, which would cause
severe burns.
Ensure hands and clothing (especially belts) are clear
of fan blades and other moving or hot parts of engine.
Remove ties and contain long hair.
DO NOT smoke or allow a spark or flame in the vicinity
of battery or engine.
DANGER! BE AWARE, LEAD ACID BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL
BATTERY OPERATION. FOR THIS REASON, IT IS
VERY IMPORTANT TO READ AND FOLLOW THESE
INSTRUCTIONS CAREFULLY, EACH TIME YOU
USE THE CHARGER.
Follow these instructions and those published by the
battery and vehicle manufacturers and the manufacturer
of any equipment you intend to use in the vicinity of
the battery. Remember to review warning marks on all
products and on engines.
1.3 PERSONAL PRECAUTIONS
Ensure there is another person within hearing range
of your voice, or close enough to come to your aid,
should a problem arise when working near a lead acid
battery.
FUSE RATING 3 AMP

4. OPERATION
Fig.1
Fig.2
Original Language Version SMC04 Issue: 1 - 31/10/13
©Jack Sealey Limited
AB
C
3.2. CHARGING A NEGATIVE EARTHED BATTERY:
3.2.1 Ensure that the black clamp on the clamp lead is not
touching the battery or the fuel line.
3.2.2 Connect the positive (+) red clamp to the positive (+)
battery post and connect the negative (-) black clamp
to the negative (-) battery post or vehicle chassis.
3.3. CHARGING A POSITIVE EARTHED BATTERY:
3.3.1 Ensure that the red clamp on the clamp lead is not
touching the battery or the fuel line.
3.3.2 Connect the negative (-) black clamp to the negative
(-) battery post and connect the positive (+) red clamp
to the positive (+) battery post or vehicle chassis.
3.4 BATTERY NOT CONNECTED TO A VEHICLE.
3.4.1 Connect the (+) red clamp to the positive (+) battery
post and connect the (-) black clamp to the negative
(-) battery post.
3.5 PERMANENT CONNECTION TO VEHICLE USING
EYELET LEAD.
3.5.1 Connect the eyelet on the red (+) wire to the positive
(+) battery terminal and connect the eyelet on the
black (-) wire to the negative (-) battery terminal.
Socket
Fully Charged Green LED
Charging Red LED
Calcium/Battery Repairing
Power On Green LED
Charging Batteries < 40Ah
Charging Batteries < 160Ah
*5°C Charging Mode
12V DC Power Supply
NOTE:Connect the charger output clamps to the battery
terminals as described in Section 3 before plugging in
to the mains power supply.
4.1 CONNECT CHARGER TO MAINS POWER SUPPLY.
4.1.1 Plug the charger into the mains power supply and
switch on. The green power LED will illuminate. See
Fig.2.
4.2 CHARGING MODE SELECTION.
Repeatedly pressing the MODE button will cycle the
charger through the following options-: MODE1,
MODE2, MODE3, MODE4 and MODE5. Stop
pressing when the LED adjacent to the desired mode
illuminates.
4.2.1 If the Mode button is pressed again during charging the
charger will switch to the next charging mode and will
function in that mode. However, once the battery is
fully charged and if the charger remains connected,
the charger will switch to trickle charge mode and will
remain in this mode even if the user selects another
mode. This protects the battery from being damaged.
4.3 MODE 1 DESCRIPTION (14.4V/2.0A)
4.3.1 This mode is suitable for charging small batteries with
a capacity below 40Ah. Press the MODE button until
the LED adjacent to the motorcycle symbol is
illuminated. Charging will automatically begin with
a current of 0.8A ± 10% and the 'charging' LED will
illuminate. This LED will remain on throughout the
entire charging process until the battery is fully charged
up to 14.4V ± 0.25V. At this stage the 'charging' LED will
extinguish and the 'fully charged' LED will illuminate.
The trickle charge current now becomes available for
battery maintenance.
*DO NOT charge a frozen battery
3.1.4 The forth lead (D) offers an opportunity of a power supply
 for12voltappliancesttedwithavehicleaccessoryplug.
The other end of the cable terminates with a plug for
connection to the charger lead socket.
BS 1363/A
UK 3 pin plug
Fault Condition Red LED
RED LED’s MODES 1, 2, 3, 4, 5.
D
Cal
Cal
Cal

5. DESCRIPTION OF CHARGING PHASES
6. MAINTENANCE
6.1 Thischargerrequiresnospecicmaintenanceother 
than cleaning which should be done with a dry cloth or a
tissue. DO NOT use any solvents or cleaning agents on
the casing.
6.2 Ensure that the charger is unplugged from the mains
before installing or performing any maintenance.
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
01284 757500
01284 703534
[e-mail]
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
Web
email
Original Language Version SMC04 Issue: 1 - 31/10/13
©Jack Sealey Limited
4.4 MODE 2 DESCRIPTION (14.4V/8.0A)
4.4.1 This mode is mainly for charging large batteries with a
capacity over 160Ah in normal conditions. Press the
MODE button until the LED adjacent to the car symbol
is illuminated. Charging will automatically begin with a
current of 3.8A ± 10% and the ‘charging’ LED will
illuminate. This LED will remain on throughout
the entire charging process until the battery is fully
charged up to 14.4V ± 0.25V. At this stage the
‘charging’ LED will extinguish and the ‘fully charged’
LED will illuminate. The trickle charge current now
becomes available for battery maintenance.
4.5 MODE 3 DESCRIPTION (14.7/8.0A)
4.5.1 This mode is mainly for charging large batteries with
a capacity over 14Ah in cold conditions or for charging
several AGM batteries with a capacity over 20Ah.
Press the MODE button until the LED adjacent to the
ice crystal symbol is illuminated. Charging will
automatically start with a set delay with a current of
3.8A ± 10% and the ‘charging’ LED will illuminate. This
LED will remain throughout the entire charging process
until the battery is fully charged; up to 14.7V ± 0.25V. At
this stage the ‘charging’ LED will extinguish and the
‘fully charged’ LED will illuminate. The trickle charge
current now becomes available for battery
maintenance.
4.6 MODE 4 DESCRIPTION (Cal)
4.6.1 This mode is for lead calcium or a battery below 10.5
volts with no capacity to absorb charging current, the
charger will automatically raise the output voltage
up to 17 volts. The Mode 4 LED will illuminate and
 ash,thechargingLEDwillilluminate.Ifthebattery
cannot be recovered within 2 hours the “Fault” (!) LED
will illuminate. The battery may require replacing.
4.7 MODE 5 DESCRIPTION(13.5v 5amp output)
4.7.1 A DC power supply for use with 12 volt appliances
 ttedwithavehicleaccessoryplug.Maximumoutput
power is 80 watts.
4.8 FAULT PROTECTION (!)
4.8.1 In the case of a short circuit, open circuit, or reversed
polarity, the charger will turn off the electronic system
and revert to standby mode. Additionally the “Fault” (!)
 LEDwillilluminate.Thefaultmustbeidentiedand
resolved before any of the charging modes are
initiated.
4.9 OVERHEATING PROTECTION
4.9.1 If the charger becomes too hot during the charging
process or due to extreme ambient temperatures the
power output is automatically reduced to a trickle
charge to protect the unit. Once the temperature drops
the charger will increase the power output automatically.
5.1 The SMC04 charger has a nine step fully automatic
charging cycle as shown in Fig.3 above, which is
indicative of the typical charging curve for a battery.
5.2 PHASE 1 through 5 DIAGNOSIS & RECOVERY:
As soon as one of the charging modes is selected the
diagnostic function automatically detects the condition
of the battery i.e. voltage. If the voltage of a deeply
discharged battery is over 7.5V ± 0.5V the charger begins
to pulse charge with a small current to recover it. Pulse
charging ceases when the voltage reaches 10.5V ±
0.5V. If the voltage detected is over 10.5V ± 0.5V the
charger skips pulse charging and switches to the
preselected charging mode.
5.3 PHASE 6 BULK: Up to 80% of the charge is delivered
in this phase.
5.4 PHASE 7 ABSORPTION: A constant low charging
current raises the voltage from 14.1V to 14.4V over a
period of time without gassing the battery. In this phase
complete charging up to almost 100% is achieved.
When full charge is reached the charger switches to
phase 8 and 9.
5.5 PHASE 8 & 9 MAINTENANCE CHARGE: If the battery
is loaded and/or the voltage across the terminals drops
below 12.8V, the charger starts a maintenance
charging pulse at a constant 0.8A until the voltage
reaches 14.4V at which point the maintenance charge
is turned off. The charger continues to monitor the
battery condition and will cycle between trickle charge
 andmaintenancechargeindenitelytokeepthe
battery in peak condition. The charger can be left
connected to the battery in order to perform this
maintenance function.
Note!
 Allguresofferedasaguideonly.Thechargeris
automatic and requires no measurements by the user.
Environmental Protection.
Recycle unwanted materials instead of disposing of them as
waste. All tools, accessories and packaging should be sorted,
taken to a recycle centre and disposed of in a manner which is
compatible with the environment.
When the product is no longer required, it must be disposed of
in an environmentally protective way.
Fig.3