Sealey SUPERSTART 520/1.V3 User manual

INSTRUCTIONS FOR:
SUPERSTART
STARTER/CHARGERS
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 DAMAGEAND/OR PERSONAL
INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will give you years of trouble free performance if these instructions are
carefully followed and the product is correctly maintained.
MODELS: SUPERSTART 520/1.V3 SUPERSTART 620/1.V3 SUPERSTART 1020.V2
1. SAFETY INSTRUCTIONS
1.2. ELECTRICAL SAFETY. p
p
WARNING! It is the users responsibility to check the following:
You must check all electrical equipment and appliances to ensure they are safe before using. You must inspect power supply leads,
plugs and all electrical connections for wear and damage. You must ensure the risk of electric shock is minimised by the installation of
appropriate safety devices. An RCCB (Residual Current Circuit Breaker) should be incorporated in the main distribution board.
We recommend that an RCD (Residual Current Device) is used with all electrical products. It is particularly important to use an RCD
with portable products that are plugged into an electrical supply not protected by an RCCB. If in 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.
1.2.1. The Electricity At Work Act 1989 requires all portable electrical appliances, if used on business premises, to be tested by a qualified
person, using a Portable Appliance Tester (PAT), at least once a year.
1.2.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of the appliance and
the safety of the appliance operator. If in any doubt about electrical safety, contact a qualified electrician.
1.2.3. DO ensure the insulation on all cables and the product itself is safe before connecting to the mains power supply. See 1.2.1. above
and use a Portable Appliance Tester (PAT).
1.2.4. DO ensure that cables are always protected against short circuit and overload.
1.2.5. DO regularly inspect power supply, leads, plugs for wear and damage and all electrical connections to ensure that none is loose.
1.2.6. DO check that the voltage marked on the product is the same as the electrical power supply to be used and check that all fused plugs
are fitted with the correct capacity fuse.
1.2.7. DO NOT pull or carry the powered appliance by its power supply lead and do not pull plug by the cable. Products must not be pulled or
carried by their output cables.
1.2.8. DO NOT use worn or damage leads, plugs or connections. Immediately replace or repair by qualified persons.
1.2.9. We do not recommend the use of an extension cable with the charger as the power output may be seriously reduced.
1.2.10. Subject to 1.1. above, the following instruction is for fitting a 13 amp plug since this will be adequate for use when charging and when
starting engines in small vehicles. No responsibility is accepted in the event that the product is misused
and/or used with a 13 amp plug when a 30 amp supply is required.
a) Connect the GREEN/YELLOW earth wire to the earth terminal E.
b) Connect the BROWN live wire to live terminal L.
c) Connect the BLUE neutral wire to the neutral terminal N.
d) After wiring, check that there are no bare wires, that all wires have been correctly
connected, that the external insulation extends beyond the cable restraint and that
the restraint is tight.
Blue
Neutral
wire
Yellow & Green
Earth wire
Brown Live
wire
13 amp
3 pin
plug
IMPORTANT : THE SUPERSTART 1020.V2 MUST BE CONNECTED TO A 3 PHASE 415 VOLT SUPPLY. ( SEE SECTION 1.3 )
IT IS RECOMMENDED THAT THE SUPERSTART MODELS 520/1.V3 & 620/1.V3 ARE CONNECTED TO A 30AMP SUPPLY.
1.1. Since January 1996 small battery chargers have been supplied with plugs fitted. Starter/chargers, however, can draw more than 13
amps from the mains supply when being used to crank large engines. For this reason therefore, starter/chargers are not supplied with
a fitted plug. We recommend that for maximum performance models 520/1.V3 & 620/1.V3 are plugged into a 30 amp electrical
supply, and further recommend that you consult an electrician in order to fit an appropriate plug.
The following statements on electrical safety must also be read and understood before using the starter/charger.
Superstart 520/1.V3, 620/1.V3,1020.V2 - 0051 - (3) - 24/06/02
1.3.1 This product must be fitted with a 3 phase plug according to the diagram to the right, and
will require a minimum of 16AMPs per phase, (preferably 32AMP) electrical supply. You must
contact a qualified Electrician to ensure an appropriately fused supply is available.
Connect GREEN/YELLOW wire to Earth E
Connect BLUE wire to R1 (or L1) Terminal.
Connect BROWN wire to S2 (L2) Terminal.
Connect the BLACK wire to terminal 3.
When completed, check there are no bare wires, that all wires have been connected
correctly and the cable restraint is tight.
1.3.2 DO NOT use this product with a standard extension cable. Only use ARMOURED extension cable.
1.3 p
p
WARNING! ELECTRICAL INSTALLATION OF THE SUPERSTART 1020 TO A 3 PHASE 415VOLT SUPPLY
MUST ONLY BE CARRIED OUT BY A QUALIFIED ELECTRICIAN. Make sure the power supply cable is correctly
connected to the Earth. It is the users responsibility to read, understand and comply with the following:
You must check all electrical equipment and appliances to ensure they are safe before using. You must inspect power supply leads,
plugs and all electrical connections for wear and damage. You must ensure the risk of electric shock is minimised by the installation
of appropriate safety devices. An RCCB (Residual Current Circuit Breaker) should be incorporated in the main distribution board.

1.5. GENERAL SAFETY INSTRUCTIONS
3Familiarise yourself with the application, limitations and potential hazards relating to starter/chargers. Also refer to the vehicle manufacturers
hand book. IF IN ANY DOUBT CONSULT AN ELECTRICIAN.
3Ensure the starter/charger is in good order and condition before use. If in any doubt do not use the unit and contact an electrician.
3Only use recommended attachments and parts. To use non-recommended items may be dangerous and will invalidate your warranty.
3Use the starter/charger in the horizontal position only and ensure it is placed on a stable surface which will adequately support the weight.
3Check the Off LED to ensure the starter/charger is registering Off before handling the power clamps.
3Ensure the starter/charger is Off before attaching/detaching the power clamps to/from the battery.
3Keep tools and other items away from the engine and ensure you can see the battery and moving parts of the engine clearly.
3Ensure the voltage on the starter/charger is set to the same voltage as the battery.
3If battery has caps to access the battery fluid, remove the caps and check the fluid level before connecting the power clamps. If necessary top-up
the battery with distilled water by referring to the battery manufacturers instructions (apply the personal safety precautions described in para. 1.3).
3The cables may become hot with excessive use. If so, allow a few minutes for them to cool down before attempting to re-use.
3If the starter/charger receives a sharp knock or blow the unit must be checked by a qualified service agent before using.
3If the battery terminals are corroded or dirty clean them before attaching the power clamps.
3Keep children and unauthorised persons away from the work area.
7DO NOT dis-assemble the starter/charger for any reason. The starter/charger must only be checked by qualified service personnel.
7DO NOT try to charge a non-rechargeable battery.
7DO NOT try to start engine, or to charge battery, if battery is frozen.
pWARNING! 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.
7DO NOT allow power clamps to touch each other or to make contact with any metallic parts of the vehicle.
7DO NOT cross connect power leads from starter/charger to battery. Ensure positive (+) (RED) is to positive and negative (-) BLACK is to negative.
If symbols cannot be distinguished, remember that the negative terminal is the one directly connected to the vehicle bodywork.
7DO NOT pull the cables or clamps from the battery terminals and DO NOT remove power clamps while the starter/charger is On.
7DO NOT use the starter/charger outdoors, or in damp or wet locations and DO NOT operate within the vicinity of flammable liquids or gases.
7DO NOT use starter/charger inside vehicle or inside engine compartment. Ensure there is sufficient ventilation and do not cover or obstruct
starter/charger ventilation louvres.
7DO NOT use this product to perform a task for which it is not designed.
pWARNING! Simultaneous charging of batteries is possible but must be done with great caution by a qualified person. Contact your
Sealey dealer for information and accessories. DO NOT charge in series two batteries of differing type, capacity, or levels of discharge.
pWARNING! If a fuse blows, ensure it is replaced with an identical fuse type and rating.
3When not in use, store the starter/charger carefully in a safe, dry, childproof location. ,
2. SPECIFICATIONS
MODEL NO: . . . . . . . . . . . . . . .S/START520/1.V3 . . .S/START620/1.V3
Output 12V Charge Peak (EN) . . . . . . . .75A (50A) . . .105A (60A) (70A)
Output 24V Charge Peak (EN) . . . . . . . .75A (50A) . . .105A (60A) (70A)
Output 12V Start Peak (EN) . . . . . . . .450A (300A) . . . . . . .540A (360A)
Output 24V Start Peak (EN) . . . . . . . .450A (300A) . . . . . . .540A (360A)
Input-Charge . . . . . . . . . . . . . . . . . . . . . . .6A/12A . . . . . . . . . . .9A/16A
Input-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . .30A . . . . . . . . . . . . . .30A
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230V . . . . . . . . . . . . .230V
Output . . . . . . . . . . . . . . . . . . . . . . . . . . .12V/24V . . . . . . . . . .12V/24V
Fuse ref. (quantity) . . . . . . . . . . . .120/121003 (2) . . . . .120/121003 (2)
Pack of 20 fuses . . . . . . . . . . . . . . . . .120/802029 . . . . . . . .120/802029
1.4. PERSONAL PRECAUTIONS
3Ensure 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.
3Wear safety eye protection and protective clothing. Avoid touching eyes while working near battery.
3Have fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
3Wash 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.
3Remove 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 the like to metal, which may cause severe burns.
3Ensure hands, clothing (especially belts) are clear of fan blades and other moving or hot parts of engine, remove ties and contain long hair.
7DO 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 CHARGING EQUIPMENT.
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.
MODEL NO: . . . . . . . . . . . . . . . . . . . . .SUPERSTART 1020.V2
Volts input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .415V 3PH
Volts output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12V/24V
Output 12V Charge Peak (EN) . . . . . . . . . . . . .120A(80A)(90A)
Output 24V Charge Peak (EN) . . . . . . . . . . . . .120A(80A)(90A)
Output 12V Start Peak (EN) . . . . . . . . . . . . . . . . . . .960A(640A)
Output 24V Start Peak ;(EN) . . . . . . . . . . . . . . . . . .960A(640A)
Input Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4A/8A
Input Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30A
Fuse Ref & quantity . . . . . . . . . . . . . . . . . . . . . .120/122452 (3)
Pack of 10 fuses . . . . . . . . . . . . . . . . . . . . . . . . . . .120/802131
3. OPERATING INSTRUCTIONS
3.1. PREPARATION It is important to correctly prepare for charging - follow Section 1 safety requirements and, especially when
charging battery in situ, any vehicle manufacturer's instructions. Check that capacity of battery is compatible with charger output.
3.1.1. Check battery to ensure the NEGATIVE & POSITIVE terminals are clearly identifiable before removing the battery from the vehicle.
3.1.2. Disconnect and remove the battery from the vehicle and place in an appropriate safe area ready for charging.
3.1.3. Remove the battery electrolyte cover or caps to allow the gases produced by charging to escape.
3.1.4. Check the electrolyte fluid level in the battery is above the plates. If not, add distilled water to cover them by 5 - 10mm.
DO NOT touch the battery fluid as it is corrosive.
3.1.5. The correct charging status of the battery may be determined by use of a hydrometer which measures the specific density of the electrolyte
The following information indicates kg/l at 20oC: 1.28 = Fully charged 1.21 = Half charged 1.14 = Fully discharged battery.
p p
WARNING! Be cautious and vigilant as the electrolyte is highly corrosive sulphuric acid.
p p
WARNING! Ensure you have read and understand all safety instructions before using the charger.
Superstart 520/1.V3, 620/1.V3,1020.V2 - 0051 - (3) - 24/06/02

3.2. CONNECTING CHARGER TO BATTERY
Ensure the battery charger is unplugged from the mains power supply before connecting power leads to the battery.
3.2.1. For chargers with dual voltage output, set the charger voltage to match that of the battery: i.e. 12 or 24 volts.
3.2.2. Check the charger clamps and battery terminals to ensure they are clean and free from oxidation.
3.2.3. Connect the charger POSITIVE (Red or +) lead to the POSITIVE (+) terminal of the battery and the NEGATIVE (Black or -) lead
to the NEGATIVE (-) terminal of the battery.
3.3. CHARGING THE BATTERY
Connect the charger to the mains power supply and set the rate of charge according to your model type as follows:
3.3.1. Superstart 520/1.V3 (see fig.A) Set the mode switch (next to the on/off switch) to the charge function indicated by the battery symbol.
Low charging rate: - select MIN & 1
Med charging rate: - select MIN & 2
High charging rate: - select MAX only (please note that when MAX is selected the switch marked 1 & 2 is over-ridden.)
The timer can be used in conjunction with the MAX setting and may be set for a charge time of up to 60 minutes. When the selected
time has elapsed the current will be switched off. For untimed functioning leave the timer knob set on normal charging.
3.3.2. Superstart 620/1.V3 (see fig.B) Select charge level 1,2 or 3 using the rotary switch situated above the timer.
3.3.3. Superstart 1020.V2 (see fig.C) Select charge level 1,2,3,4 or 5 using the rotary switch situated to the right of the timer.
( Ensure that the mode switch below the timer is set to normal charging.)
3.3.4 Once you have checked that the charger is correctly set up for the current situation, switch on the power.
3.3.5. Check the current delivery to the battery by reading the ammeter on the front of the battery charger (fig D ammeter face may vary by
model). Initially, there will be a high rate of charge which will slowly decrease according to the capacity and condition of the battery.
3.3.6. When fully charged the ammeter reading should be close to 0 and the electrolyte in the battery should begin to gas. Stop charging to
protect battery plates from oxidisation and damage.
3.3.7. Switch charger off and unplug from mains power. Disconnect the power clamps, clean the charger and store in a safe, dry area.
3.3.8. Replace the battery electrolyte cover or caps. Wipe up any splashes or spillage (remember the electrolyte is a corrosive acid). Return
the battery to the vehicle, secure according the manufacturers instructions and re-connect the power leads. Check to ensure all
tools are removed before closing the bonnet.
fig D
fig E
3.4. RAPID CHARGE
The Superstart 620/1.V3 and the 1020.V2 both have a rapid
charge function which is controlled by the 60 minute timer
provided. Rapid charging takes place at a pre-set rate which
is one step higher than the highest charge rate available
during normal charging.
Superstart 620/1.V3 To initiate rapid charging turn the timer
to the required charging time in minutes and turn the rotary
selector switch to the rapid charging position indicated by a
hare symbol (see fig.E). When the pre-set time has elapsed
the current is automatically switched off. Turn the rotary
selector switch to the off position.
Superstart 1020.V2 To initiate rapid charging set the rocker
switch below the timer to rapid charging indicated by a hare
symbol then turn the timer to the required charging time in
minutes. Turn the rotary power switch to position 2 which
also has the rapid charging symbol associated with it. When
the pre-set time has elapsed the current is automatically
switched off. When rapid charging is no longer required
remember to select normal charging on the rocker switch
below the timer.
Superstart 520/1.V3, 620/1.V3,1020.V2 - 0051 - (3) - 24/06/02
NOTE: If charger is connected to a fully charged battery the ammeter will show a low charging output. NO charging is necessary.
DO NOT continue to charge a fully charged battery, as this will damage the battery. DO NOT leave a battery on charge unattended.
3.5. STARTING A VEHICLE WITH A FLAT BATTERY
Your starter/charger will deliver sufficient output to start an appropriate size of vehicle with a flat battery.
To charge a battery under normal circumstances refer to 3.3. To start a vehicle which has a flat battery proceed as follows:
3.5.1. Check the vehicle manufacturers handbook and follow any special instructions. Check that the battery is in good condition.
3.5.2. 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. 12 or 24 volts.

Declaration of Conformity We, the sole importer into the UK, declare that the products listed here
are in conformity with the following standards and directives
For Jack Sealey Ltd. Sole importer into the UK of Sealey Power Products.
27th June 2002
Signed by Mark Sweetman
The construction files for these products are held by the Manufacturer and may be inspected, by a
national authority, upon request to Jack Sealey Ltd.
BATTERY STARTER/CHARGER Models:
Superstart 520/1.V3, 620/1, 1020
89/336/EEC EMC Directive
73/23/EEC LV Directive
4. FUSES
Your starter/charger is equipped with a safety fuse, or fuses, which will cut the power to 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.
Should the fuse blow take the following action:
4.1. Turn the unit off and disconnect from the mains power supply.
4.2. Allow the unit to cool down, establish the reason for failure and correct.
4.3. Replace the fuse (for some models remove small panel at rear of starter/charger). Use only Sealey replacement fuse. DO NOT use a
fuse with copper bridges or similar as these will damage your equipment. Refer to Section 2 Specifications for fuse information and part
numbers. We recommend you hold 2 or 3 spare fuses with the starter/charger.
Note: The use of an incorrect fuse will invalidate your warranty.
Sole UK Distributor,
Sealey Group,
Bury St. Edmunds, Suffolk. 01284 757500
E-mail: [e-mail]
01284 703534
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 the 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.
Superstart 520/1.V3, 620/1.V3,1020.V2 - 0051 - (3) - 24/06/02
3.5.4. Check that the charger clamps and battery terminals are clean and free from oxidation.
3.5.5. Without removing the power leads that connect the battery to the vehicle, connect the charger POSITIVE (red) lead to
the POSITIVE (+) terminal on battery and the NEGATIVE (black) lead to NEGATIVE (-) terminal on the battery.
3.5.6. Plug starter/charger into mains power supply, select a low rate of charge and turn on. Allow the battery to charge for 2-3 minutes.
3.5.7. Superstart 520/1.V3 & 620/1.V3 Turn the appropriate switch to the Start position (indicated by the
symbol seen in fig 2) and wait for approximately 25 seconds (to allow charge to build). Turn the vehicle
ignition on and crank the engine for a MAXIMUM of 10 seconds. If the vehicle does not start, wait 30
seconds and then try again.
Superstart 1020.V2 remote start button. The Superstart 1020 has a remote start button on an
extended lead. When the rotary switch on the unit is turned to the Start position the boost charge is not initiated until the button on
the remote is pressed. The charge will continue as long as the button is held down and cease when the button is released. This
facility is particularly useful when working on commercial vehicles where the button can be taken into the cab. Turn the ignition on
and crank the engine followed immediately by the operation of the remote start button. If the vehicle does not start within 10
seconds release the button and turn off the ignition. Wait 30 seconds and then try again.
pWARNING! If the vehicle does not start after two attempts, DO NOT continue as vehicle battery and electrical circuits may
be damaged, and the fuse in the charger will blow. Disconnect the charger and investigate for vehicle faults
3.5.8. When the vehicle is running successfully, switch the starter/charger off, unplug from the mains power and disconnect the power
terminals from the battery. DO NOT attempt to start engine with starter/charger if the battery is disconnected from the vehicle.
fig 2