Sealey SUPERBOOST140.V5 User manual

SUPERBOOST STARTER / CHARGER
MODEL NOS: SUPERBOOST140.V5 & SUPERBOOST160.V6
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.
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qualied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.
 TheElectricityatWorkAct1989requiresthatallportableelectricalappliances,ifusedonbusinesspremises,aretestedbyaqualied
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qualied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 leads, plugs for wear and damage and power connections, to ensure that none is loose or damaged.
1.1.6. 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.
1.1.7. ThisproductisttedwithaBS1363/A3pinplug.
 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.
 ReplaceadamagedplugwithaBS1363/A3pinplug.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’.
Ensure that the cable outer sheath extends inside the cable restraint and that the restraint 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.AreelwithanRCDtted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. If extension reel is to be used outdoors, ensure it is marked for outdoor use.
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.
Follow 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.
9 Noliabilitywillbeacceptedfordamage/injury,wherethisproductisnotusedinaccordancewithallinstructions.
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.
Original Language Version
© Jack Sealey Limited
Refer to
instructions Electrical shock hazard
Wear eye
protection
Wear
protective
gloves
Warning
corrosive
substance
Keep away
from sources
of ignition
Use in well
ventilated
areas
Keep in dry
area, protect
from rain
Warning
Replacement fuse
rating: 13A
SUPERBOOSTSeries140.V5,160.V6Issue127/06/23

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.
9 Washimmediatelywithsoapandwaterifbatteryacidcontactsskinorclothing.Ifacidenterseye,ush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 moving or hot parts of engine, remove ties and contain long hair.
8DO NOTsmokeorallowasparkorame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INANY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.
9 Usethestarter/chargerintheuprightpositiononlyandensureitisplacedonastablesurfacewhichwilladequatelysupportitsweight.
9 Ensure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.
9 Ensurethatduringcharging,thechargerisplacedinalocationwherethereissu󰀩cientventilationtopreventthebuildupofexplosive
gases from a lead acid battery, and DO NOT cover or obstruct the charger ventilation louvres.
9 Ifbatteryhascapstoaccessthebatteryuid,removethecapsandchecktheuidlevelbeforeconnectingthepowerclamps.
9 Ifnecessarytop-upthebatterywithdistilledwaterbyreferringtothebatterymanufacturer’sinstructions(Applythepersonalsafety
precautions described in part 1.3).
9 Ifthechargerreceivesasharpknockorblowtheunitmustbecheckedbyaqualied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.
9 Ensurethereise󰀨ectiveventilationtopreventabuild-upofexplosivegases,andDO NOT cover or obstruct charger ventilation
louvres.
9When not in use, store the charger carefully in a safe, dry, childproof location.
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di󰀨erentcapacitiesordischargelevels.
WARNING! If a fuse blows, ensure it is replaced with an identical fuse type and rating. Use only Sealey genuine parts.
8DO NOTdis-assemblethechargerforanyreason.Thechargermustonlybecheckedbyqualiedservicepersonnel.
8DO NOT try to charge a non-rechargeable battery.
8DO NOTtrytochargebatteryifbatteryuid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terminalandnegative(-/BLACK)is
to negative terminal.
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ammable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unitwithtwochargesettingsandastartfunctiontojumpstartvehicleswithaat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
eetoperatorsrunningcarsandvanderivatives.Built-inpolarityprotection.
3. SPECIFICATION
MODEL NO. SUPERBOOST140.V5 SUPERBOOST160.V6
Cable and Clamp Length 2m 2m
Fuse Rating 13A 13A
Plug Type 3-Pin BS 3-Pin BS
Original Language Version
© Jack Sealey Limited SUPERBOOSTSeries140.V5,160.V6Issue127/06/23

3.1.
3.2.
.
Power Supply Cable 2m 2m
Supply 230V 230V
Output 12V/24V 12V/24V
Output Charge Peak (EN) 21A (14A) 30A (20A)
Battery Range 15-240Ah 125-300Ah
Output Start Peak (EN) 140A (110A) 160A (140A)
Input Charge 2.7A 3.5A
Input Start 11A 12.5A
Polarity Protection Fuse (1 x 50A) Fuse (1 x 80A)
Charging Rates 3 3
Fuse 120/802309(Packof20) 120/802260(Packof20)
120/12235(Single)
4. OPERATION
4.1. PREPARATION
4.1.1. 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.
4.1.2. Followanyvehiclemanufacturer’sinstructionsregardingbatterycharging.Notespecialinstructionsforin-vehiclecharging.
4.1.3. CheckbatterytoensurethattheNEGATIVEandPOSITIVEterminalsareclearlyidentiablebeforeremovingbatteryfromthevehicle.
4.1.4. Subjectto4.1.1.above,disconnectandremovethebatteryfromthevehicleandplaceinanappropriatesafeareareadyforcharging.
4.1.5. Remove the battery electrolyte cover or caps to allow the gases produced by charging to escape.
4.1.6. Check that the electrolyte is covering the plates inside. If not, add distilled water so that the plates are covered by 5-10mm.
4.1.7. Thecorrectchargingstatusofthebatterymaybedeterminedbyuseofahydrometerwhichwillmeasurethespecicgravityofthe
 electrolyte.Thefollowinggures(kg/l)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
4.2.1. Ensure that the battery charger is unplugged from the mains power supply before connecting the clamps to the battery.
4.2.2. 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.
4.2.3. Set the mode switch to “Charge”, indicated by the battery symbol.
4.2.4. Settherateofchargetothatrequiredbyusingthechargelevelswitchesasshowning.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.
4.2.5. Check that the charger clamps and battery terminals are clean and free from oxidation.
4.2.6. 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(g.1).
4.3.2. Checkthecurrentdeliverytothebatterybyreadingtheammeteronthefrontofthebatterycharger(g.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g.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rstbeforeselectingboostonthefrontpanel(g.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
4.3.5. 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o󰀨automatically.Thestateofchargeshouldberegularlymonitoredbytheoperator.DO NOT
leave the charger operating unattended or overnight.
4.3.6. Switchthechargero󰀨andunplugfromthemainspowersupply.Disconnectthepowerclamps,cleanandstorethechargerinasafe,
dry area.
4.3.7. NOTE: SUPERBOOST140 Boost duty cycle is ON 40 minutes, OFF 20 minutes. SUPERBOOST160 ON 15minutes, OFF 20 minutes.
4.3.8. Replace the battery electrolyte cover or caps. Wipe up any splashes or spillage (remember that the electrolyte is a corrosive acid).
4.3.9. 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.
Fig 1 Fig 2
Original Language Version
© Jack Sealey Limited SUPERBOOSTSeries140.V5,160.V6Issue127/06/23

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
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g.3.
4.5.2. Two12voltbatteriesmaybechargedsimultaneouslyinseriesusinga24voltoutputchargerasshowning.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.
5.5.1. Check the vehicle manufacturer's handbook and follow any special instructions. Check that the battery is in good condition.
5.5.2. 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.
5.5.3. Check the charger clamps and battery terminals to ensure they are clean and free from oxidation.
5.5.4. 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.
5.5.5. 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.
5.5.6. 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.
5.5.7. Whenthevehicleisrunningswitcho󰀨thestarter/charger,unplugfromthemainspoweranddisconnectpowerterminalsfrombattery.
6. SAFETY FUSE
6.1. 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.
6.2. If the fuse blows take the following action:
6.3.  Turntheunito󰀨anddisconnectfromthemainspowersupply.
6.4. Allow the unit to cool down, establish the reason for failure and correct the situation.
6.5.  Replacethefuse(underthefusecoveronthecontrolpanel).UsingonlySealeyreplacementparts.RefertoSpecication(section3)
for details.
WARNING! DO NOT use a fuse with a copper bridge or similar as this will damage the equipment.
Charging in Parallel Charging in Series
++
12V
24V
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.
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. Please note that other versions of this product are available. If you require documentation for alternative versions, please email or call
our technical team on [e-mail] or 01284 757505.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
WEEE REGULATIONS
Dispose of this product at the end of its working life in compliance with the EU Directive on Waste Electrical and Electronic Equipment
(WEEE). When the product is no longer required, it must be disposed of in an environmentally protective way. Contact your local solid
waste authority for recycling information.
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PURCHASE HERE
Fig 3 Fig 4
Original Language Version
© Jack Sealey Limited SUPERBOOSTSeries140.V5,160.V6Issue127/06/23
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 [e-mail] www.sealey.co.uk