Sealey Superboost 180.v6 User manual

SUPERBOOST STARTER / CHARGER

MODEL NOS: SUPERBOOST 180.V6 &SUPERBOOST 200.V5

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 & CAUTIONS. USE

THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR

PERSONAL INJURYAND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.

1. SAFETY

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 a RCCB. If in any doubt consult a qualified electrician. You may obtain a Residual Current

Device by contacting your Sealey stockist.

1.1.1. You must also read and understand the following instructions concerning electrical safety.

1.1.2. 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.

1.1.3. 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.

1.1.4. 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.

1.1.5. Ensure that cables are always protected against short circuit and overload.

1.1.6. Regularly inspect power supply leads, plugs for wear and damage and power connections, to ensure that none is loose or damaged.

1.1.7. Important: Ensure that the voltage rating on the appliance suits the power supply to be used and that the plug is tted with the correct

fuse - see fuse rating in these instructions.

8DO NOT pull or carry the appliance by the power cable.

8DO NOT pull the plug from the socket by the cable.

8DO NOT use worn or damaged cables, plugs or connectors. Ensure that any faulty item is repaired or

replaced immediately by a qualied electrician.

1.1.8. This product requires a 16Amp 3 pin plug. (Not supplied)

If the cable or plug is damaged during use, switch the electricity supply o󰀨 and remove from use.

Ensure that repairs are carried out by a qualied electrician.

If in doubt contact a qualied electrician.

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 there are no bare wires, that all wires have been correctly connected, that the

cable outer insulation is clamped by the cable grip and that the grip is tight.

Sealey recommend that repairs are carried out by a qualied electrician.

If an extension reel is used it should be fully unwound before connection. We recommend the use of 2.5mm² section cable.

1.2. GENERAL SAFETY

▲DANGER! BE AWARE, LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION.

FOR THIS REASON, IT VERY IMPORTANT TO READ AND FOLLOW THESE INSTRUCTIONS CAREFULLY, EACH TIME YOU USE

THE CHARGING EQUIPMENT.

9Follow these instructions and those published by the battery and vehicle manufacturers, and the maker of any equipment you intend to

use in the vicinity of the battery. Remember to review warning marks on all products and on engines.

WARNING! Modern vehicles contain extensive electronic systems.

You are required to check with the vehicle manufacturer, for any specic instructions regarding the use of this type of equipment on

each vehicle.

9No liability will be accepted for damage / injury, where this product is not used in accordance with all instructions.

Original Language Version

Wear

protective

gloves

Warning:

electricity Protect

from

rain

Use in

well

ventilated

areas

Keep away

from sources

of ignition:

battery could

explode

Refer to

instruction

manual

Warning:

explosive

material

Wear eye

protection Warning:

corrosive

substance

Recommended fuse

rating:

16A

SUPERBOOST SERIES: 180.V6, 200.V5 Issue 1 27/06/23

NOTE: Children from age 8 years and above, persons with reduced physical, sensory, or mental capabilities those with lack of

experience and knowledge can use the appliance, if they have been given supervision or instruction concerning use of the appliance

in a safe way to understand the hazards involved.

9Children shall NOT play with the appliance.

9Cleaning and user maintenance on the appliance shall not be made by children without supervision. That the appliance shall be

disconnected from its power source during service and when replacing parts and, if that the removal of the plug is foreseen,

it shall be clearly indicated that the removal of the plug has to be such that an operator can check from any of the points to which

he has access that the plug remains removed.

9During charging, the battery must be placed in a well-ventilated area.

9The battery charger must only be plugged into an earthed socket-outlet.

9 The battery terminal not connected to the chassis has to be connected rst. The other connection is to be made to the chassis, remote

from the battery and fuel line. The battery charger is then to be connected to the mains supply.

9 The battery terminal not connected to the chassis has to be connected rst. The other connection is to be made to the chassis, remote

from the battery and fuel line. The battery charger is then to be connected to the supply mains

9Examine the battery charger regularly for damage, especially the cord, plug and enclosure. If the battery charger is damaged, it

must not be used until it has been repaired by the manufacturer, its service agent or similarly qualied persons in order to

avoid a hazard.

9 If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualied persons in order to

avoid a hazard.

1.3. PERSONAL PRECAUTIONS

9Ensure there is another person within hearing range of your voice and close enough to come to your aid, should a problem arise when

working near a lead-acid battery.

9Wear safety eye protection and protective clothing.Avoid touching eyes while working near battery.

9Have fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.

9Wash 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.

9Remove personal metallic items such as rings, bracelets, necklaces and watches. A lead-acid battery can produce a short-circuit current

which is high enough to weld a ring or the like to metal, which would cause severe burns.

9Ensure hands, clothing (especially belts) are clear of fan blades and other moving or hot parts of engine, remove ties and contain long hair.

8DO NOT smoke or allow a spark or flame in the vicinity of battery or engine.

1.4. CHARGING SAFETY INSTRUCTIONS

9Familiarise yourself with the application and limitations of the charger as well as the potential hazards. Also refer to the vehicle

manufacturer’s hand book. IF INANY DOUBT CONSULT A QUALIFIED ELECTRICIAN.

9Ensure the charger is in good order and condition before use. If in any doubt do not use the unit, contact your Sealey stockist.

9Use the starter/charger in the upright position only and ensure it is placed on a stable surface which will adequately support its weight.

9Ensure the charger is disconnected from the mains supply before attaching/detaching the power clamps to/from the battery.

9Keep tools and other items away from the engine and ensure you can see the battery and working parts of engine clearly.

9Ensure the output of the charger is the same voltage as the battery.

9Ensure that during charging, the charger is placed in a location where there is sufficient ventilation to prevent the build up of explosive

gases from a lead acid battery, and DO NOT cover or obstruct the charger ventilation louvres.

9If battery has caps to access the battery fluid, remove the caps and check the fluid level before connecting the power clamps.

9If necessary top-up the battery with distilled water by referring to the battery manufacturer’s instructions (Apply the personal safety

9precautions described in part 1.3).

9If the charger receives a sharp knock or blow the unit must be checked by a qualified service agent before using.

9If the battery terminals are corroded or dirty clean them before attaching the power clamps.

9Keep children and unauthorised persons away from the working area.

9When not in use, store the charger carefully in a safe, dry, childproof location.

9Ensure there is effective ventilation to prevent a build-up of explosive gases, and DO NOT cover or obstruct charger ventilation louvres.

WARNING! If a fuse blows, ensure it is replaced with an identical fuse type and rating. Use only Sealey genuine parts.

WARNING! To prevent the risk of sparking, short circuit and possible explosion DO NOT drop metal tools in the battery area, or allow

them to touch the battery terminals.

WARNING! DO NOT simultaneously charge batteries of different capacities or discharge levels.

8DO NOT dis-assemble the charger for any reason. The charger must only be checked by qualified service personnel.

8DO NOT try to charge a non-rechargeable battery.

8DO NOT try to charge battery if battery fluid is frozen.

8DO NOT allow power clamps to touch each other or to make contact with any metallic part of the vehicle.

8DO NOT cross connect power leads from charger to battery. Ensure positive (+/RED) is to positive and negative (-/BLACK) is to negative.

8DO NOT pull the cables or clamps from the battery terminals.

8DO NOT use the charger outdoors, or in damp, or wet locations and DO NOT operate within the vicinity of flammable liquids or gases.

8DO NOT use charger inside vehicle or inside engine compartment.

8DO NOT use the charger for a task for which it is not designed.

2. INTRODUCTION

Combination units with two charge settings and a start function to jumpstart vehicles with a flat battery. Features easy-to-read ammeter and

illuminated power switch. Dual output (12 and 24V) and circuitry is protected by a panel mounted fuse. Suitable for garages, workshops and fleet

operators running cars and van derivatives. Built-in polarity protection.

3. i SPECIFICATION

Original Language Version

MODEL NO. SUPERBOOST180.V6 SUPERBOOST200.V5

Cable and Clamp Length 2m 2m

Fuse Rating N/A N/A

Plug Type Bare Wire Bare Wire

4. i OPERATION

4.1. PREPARATION

It is important to correctly prepare for charging, ensuring that you follow Section 1 safety regulations carefully. Check that the capacity

of the battery is compatible with the charger output.

4.1.1. Follow any vehicle manufacturer’s instructions regarding battery charging. Note special instructions for in-vehicle charging.

4.1.2. Check the battery to ensure that the NEGATIVE and POSITIVE terminals are clearly identifiable before removing the battery from the vehicle.

4.1.3. Subject to 4.1.1. above, disconnect and remove the battery from the vehicle and place in an appropriate safe area ready for charging.

4.1.4. Remove the battery electrolyte cover or caps to allow the gases produced by charging to escape.

4.1.5. Check that the electrolyte is covering the plates inside. If not, add distilled water so that the plates are covered by 5-10mm.

4.1.6. The correct charging status of the battery may be determined by use of a hydrometer which will measure the specific gravity of the electrolyte.

The following figures (kg/ltr) apply at 20°C: 1.28 = Fully charged, 1.21 = Half charged, 1.14 = Fully discharged.

WARNING! Be cautious and vigilant as the electrolyte is a highly corrosive acid.

4.2. CONNECTING THE CHARGER TO THE BATTERY

Ensure that the battery charger is unplugged from the mains power supply before connecting the clamps to the battery.

4.2.1. For chargers with dual voltage output set the charger voltage to match that of the battery voltage (i.e. 12 or 24 volts) by connecting the

positive (red) clamp lead to either the 12 volt output terminal or the 24 volt output terminal as appropriate.

4.2.2. Set the mode switch to “Charge”, indicated by the battery symbol.

4.2.3. Set the rate of charge to that required by using the charge level switches as shown in fig. 1. The MIN & BOOST switch relates to charge

levels only. When the charge level is set to BOOST the switch marked 1 & 2 is over-ridden.

4.2.4. Check that the charger clamps and battery terminals are clean and free from oxidation.

4.2.5. Connect the POSITIVE (Red or +) lead to the POSITIVE (+) terminal on the battery and the NEGATIVE (Black or -) lead to the NEGATIVE (-)

terminal on the battery.

4.3. CHARGING THE BATTERY

4.3.1. Connect the charger to the mains power supply and switch on using front panel mounted ON / OFF switch (fig.1).

4.3.2. Check the current delivery to the battery by reading the ammeter on the front of the battery charger (fig.2). During charging the pointer on

the ammeter will slowly decrease (move to the left) according to the capacity and condition of the battery (see fig. 2, dial face may vary

according to model of charger).

4.3.3. If a boost charge is required ensure that an initial charge has built up first before selecting boost on the front panel (fig.1).

4.3.4. When the battery is fully charged the reading on the ammeter should be at the “0” output indicator. At this point the electrolyte in the

battery will begin to bubble. Stop charging at this point in order to protect the battery plates from oxidisation and to keep the battery in

good condition.

WARNING: The charger will not switch off automatically. The state of charge should be regularly monitored by the operator. DO NOT

leave the charger operating unattended or overnight.

4.3.5. Switch the charger off and unplug from mains power supply. Disconnect power clamps, clean and store the charger in a safe, dry area.

4.3.6. NOTE: SUPERBOOST180 and SUPERBOOST200 have Boost duty cycle of ON: 15 minutes, OFF: 20 minutes.

4.3.7. Replace the battery electrolyte cover or caps. Wipe up any splashes or spillage (remember that the electrolyte is a corrosive acid).

Return the battery to the vehicle and secure according the manufacturer’s instructions. Reconnect the power leads. Check to ensure all

tools etc. are removed before closing the bonnet or boot.

4.4. LOW or NO MAINTENANCE BATTERIES

4.4.1. When charging a low, or no maintenance battery take very special care to use only a “LOW” charge setting. Use a battery tester to

continually check the voltage across the clamps.

4.4.2. When the battery terminal voltage reaches 14.4 volts for 12V batteries or 28.8 volts for 24V batteries stop the charging process.

4.5. MULTIPLE BATTERY CHARGING

fig.1

Original Language Version

fig.2

Power Supply Cable 2m 2m

Supply 230V 230V

Output 12V/24V 12V/24V

Output Charge Peak (EN) 40A (25A) 45A (30A)

Battery Range 20-400Ah 3-500Ah

Output Start Peak (EN) 180A (160A) 200A (210A)

Input Charge 4.5A 5.4A

Input Start 15.5A 19.5A

Polarity Protection Fuse (1 x 80A) Fuse (1 x 110A)

Charging Rates 3 3

Fuse 120/802260 (Pack of 20) START180.F20 (Pack of 20)

SUPERBOOST SERIES: 180.V6, 200.V5 Issue 1 27/06/23

WARNING: DO NOT attempt to simultaneously charge di󰀨erent types of batteries or batteries with di󰀨erent capacities or levels of

charge.

4.5.1. A number of batteries may be charged at the same time. To do so we recommend parallel connection as shown in fig.3.

4.5.2. Two 12 volt batteries may be charged simultaneously in series using a 24 volt output charger as shown in fig.4. This is only

recommended if both batteries are of similar capacity and in a similar state of discharge.

5. STARTING

WARNING! DO NOT attempt to start engine with starter/charger if the battery is disconnected from the vehicle. The presence of the

battery is essential for the elimination of possible over-voltage that may be generated due to energy accumulating in the connection

cables at the starting stage.

5.1. Check the vehicle manufacturers handbook and follow any special instructions. Check that the battery is in good condition.

5.2. Ensure the starter/charger is disconnected from the mains power supply and for models with dual voltage output set the output voltage

to the same as the vehicle battery i.e. either 12V or 24V.

5.3. Check the charger clamps and battery terminals to ensure they are clean and free from oxidation.

5.4. Without removing the cables that connect the battery to the vehicle connect the charger POSITIVE (red) lead to the POSITIVE (+)

terminal on the battery and the NEGATIVE (black) lead to the NEGATIVE (-) terminal on the battery.

5.5. Starting will be enhanced if the battery is given a short charge prior to turning the ignition switch. This must always be done with the

selector switch (g.1) set to the charge position and NOT to Boost. Plug starter/charger into mains power, select a low rate of charge

and turn on. Allow the battery to charge for 2-3 minutes.

5.6. Move the starter/charger switch to the START position (g.1). Turn the vehicle ignition on and crank the engine for a MAXIMUM of 3

seconds. If the vehicle does not start, wait for 2 minutes and repeat for a MAXIMUM of 5 cycles then allow 30 minutes rest.

WARNING! If the vehicle will not start DO NOT continue as the vehicle battery and electrical circuits may be damaged and the fuse in

the charger will fail. Disconnect the charger and investigate the vehicle for faults.

5.7. When the vehicle is running switch o󰀨 the starter/charger, unplug from the mains power and disconnect the power terminals from the

battery.

6. SAFETY FUSE

The charger is equipped with a fuse which will protect the unit in the following circumstances:

a) Overload: Too high a current to the battery.

b) Short circuit: Clamps touch, or cross-connection to battery.

c) Prolonged starting attempts.

If the fuse blows take the following action:

6.1. Turn the unit off and disconnect from the mains power supply.

6.2. Allow the unit to cool down, establish the reason for failure and correct the situation.

6.3. Replace the fuse (under the fuse cover on the control panel). Using only Sealey replacement parts. Refer to Specification (section 3)

for details.

WARNING! DO NOT use a fuse with a copper bridge or similar as this will damage the equipment.

ENVIRONMENT PROTECTION

Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to

a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely

unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids

according to local regulations.

Original Language Version

Charging in Parallel Charging in Series

12V

24V

Fig 3 Fig 4

SUPERBOOST SERIES: 180.V6, 200.V5 Issue 1 27/06/23

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