Sealey Superstart300.v5 User manual

INSTRUCTIONS FOR

STARTER/CHARGER 300AMP,400AMP,500AMP

12/24V

MODEL NO: SUPERSTART300.V5/SUPERSTART

400.V2/SUPERSTART500.

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 INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.

1. SAFETY

Electrical Safety

WARNING! It is the user’s responsibility to check the following:

Check all electrical equipment and appliances to ensure that they are safe before using. Inspect power supply leads, plugs and

all electrical connections for wear and damage. Sealey recommend that an RCD (Residual Current Device) is used with all electrical

products. You may obtain an RCD by contacting your local Sealey dealer.

If the charger is used in the course of business duties, it must be maintained in a safe condition and routinely PAT (Portable Appliance

Test) tested.

Electrical safety information, it is important that the following information is read and understood.

1.0.1. Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply.

1.0.2. Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure

that they are secure.Important: Ensure that the voltage rating on the appliance suits the power supply to be

 usedandthecorrecttypeofplugtted.

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

8DO NOTpulltheplugfromthesocketbythecable.Removetheplugfromthesocketbymaintainingarm

grip on the plug.

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.

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

1.0.4. This product requires an electrical supply in excess of 13 amps, and NO plug is fitted.

You must therefore contact a qualified electrician to ensure that a 16 amp supply is available.

We recommend that you discuss the installation of a industrial round pin plug and socket with your electrician.

Ensure that the unit is correctly earthed via a three-pin plug, as shown.

a) Connect the green/yellow earth wire to the earth terminal

b) Connect the brown live wire to live terminal ‘L’.

c) Connect the blue neutral wire to the neutral terminal, ‘N’ or unmarked.

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.

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

 “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.”

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

▲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.

1.0.5.

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.

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

1.1. 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.

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

It is recommended

that the supply to this

productisttedwitha

16AMP Fuse or Breaker

SUPERSTART300.V5,400.V2,500. | Issue (1) 05/07/16

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.

Ensure 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.

1.2. General 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 Dealer.

9Use the 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. 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 1.2).

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.

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.

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.

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.

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

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

WARNING! DO NOT simultaneously charge batteries of different 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.

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

2. INTRODUCTION

Heavy-duty professional starter/chargers for the medium and large garage, workshop and body shop operation. The SuperStart range caters for all

requirements from cars right up to passenger service and commercial vehicles.

Model No: ......................SUPERSTART300.V5......................SUPERSTART400.V2......................SUPERSTART500

Output: .........................12-24V..............................................12/24V...............................................12/24V

Output Charge Peak (EN): .......... 45A(30A)..........................................60A(40A)...........................................75A(50A)

Output Start Peak(EN):.............300A(200A)......................................400A(300A).......................................500A(350A)

Battery Range: . . . . . . . . . . . . . . . . . . . 30-350Ah..........................................30-450Ah..........................................30-550Ah

Input Charge: ....................1.5KW...............................................1.5KW................................................1.5KW

Imput Start:...................... 5KW..................................................6KW...................................................10KW

Charging Rates: . . . . . . . . . . . . . . . . . . 4........................................................4........................................................4

Supply: . . . . . . . . . . . . . . . . . . . . . . . . . 230V..................................................230V..................................................230V

Polarity Protection: ................Fuse(1x80A)......................................Fuse(2x80A).....................................Fuse(2x80A)

3. ASSEMBLY

3.1. Assemble the handle to the main casing using the fittings provided as indicated in fig.1

3.2. Slide the axle through the casing at the bottom back corner. Attach the wheels using the fittings provided as indicated in fig.1.

3.3. The clamp with the red handle is attached to the movable cable. see fig1A

3.4. The clamp with the black handle is attached to the fixed cable which comes directly out of the top of the battery charger. see fig1A

Original Language Version

Fig 1

4. PREPARATION

4.1. The battery charger will only charge free-electrolyte lead batteries having the following number of elements: 6 for 12-volt

batteries, 12 for 24-volt batteries.

4.2. Before charging, check the state of the battery.

4.2.1. Remove the caps or the special fasteners of the battery.

4.2.2.

Make sure the electrolyte level covers the battery plates; otherwise add distilled water until they are covered by 5/10 mm.

4.2.3. The exact state of the battery can only be determined with a densimeter which measures the specific density of the

electrolyte. Battery charge conditions can be checked according to the following solute density values (Kg/l at 20°C):

1.28 battery charged - 1.21 battery half-charged - 1.15 battery flat.

4.3. Proceed with charging, by carrying out the following steps and in the same order:

4.3.1.

Before charging, make sure the power supply lead is not plugged into the mains supply.

4.3.2.

Set the charger voltage 12V or 24V according to the nominal voltage of the battery being charged, by moving the red cable

to the appropiate terminal. * Note: To charge several batteries at the same time see the series/parallel diagram in fig. 2

4.3.3. Connect the output wire with red clamp to the positive terminal (+) of the battery

4.3.4. Connect the other output wire with black clamp to the negative terminal (-) of the battery, or in case of direct charge,

connect it directly to the vehicle’s chassis at a good distance from the battery or from the fuel pipe.

Control

Panel

4.4. Charging the Battery

4.4.1. Position the current adjustment diverters according to the capacity of battery to charge:

Fig.2

Fig.3

Original Language Version

Fig.4

Fig1A

4.4.2. Note: It is always a good rule to carry out charging by adjusting the current to one tenth the battery’s nominal capacity for

approximately 10/15 hours. For small capacity batteries adjust the current to minimum and let charge for no more than 4/5 hours.

4.5. Connect the power supply lead to the mains, making sure the voltage matches the nominal voltage of the battery charger.

4.5.1. Turn the switch to “ON” (if present). If everything is correctly connected the ammeter (present on the battery charger) will indicate the

initial charging current.

4.5.2. Note: If the battery charger is adjusted to a minimum current level and is connected to an almost fully-charged battery, the

 ammetershowverylowcurrent.g.5

4.5.3.When the battery is fully charged the ammeter reading should be close to “0” and the electrolyte in the battery should begin to

gas. Stop charging to protect the battery plates from oxidisation and damage.

4.5.4. Turn the switch (if present) to “OFF”, and/or disconnect the power supply lead from the mains.

4.5.5. Disconnect the output leads in this order: the black clamp from the vehicle’s chassis or negative pole (-), the red clamp from

the positive pole (+) of the battery.

4.5.6. Close the battery cells with the caps or the special fasteners.

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

4.6. Start Function

4.6.1. In battery chargers with the START function, help in starting the vehicle is possible whenever the battery does not have enough

power to turn the starter motor. It is advisable to carry out a fast battery charge before switching to the start the engine.

WARNING! If the vehicle will not start, 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.

4.6.2.

When the vehicle is running successfully, switch the starter/charger off, unplug from the mains power and disconnect the power terminals

from the battery.

5. FUSE

5.1. The starter/charger is equipped with a safety fuse, or fuses, which will cut the power to the unit in the following circumstances:

5.1.1. Overload - too high a current to the battery.

5.1.2. Short circuit - clamps touch, or cross-connection to battery.

5.1.3. Prolonged starting attempts.

5.2. Should the fuse blow take the following action:

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

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

5.2.3. Replace the fuse. Use only Sealey replacement fuses. DO NOT use a fuse with copper bridges or similar as these will damage your

equipment. We recommend you hold 2 or 3 spare fuses with the starter/charger.

5.2.4. Battery chargers are equipped with thermostatic overcharge protection, wait a few minutes for automatic resetting after its intervention.

6. MAINTENANCE

6.1. When the battery charger is not being used, it must be stored in a dry place to protect it against humidity. Disconnect the battery

charger and use a soft cloth to clean its outer casing.

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

Fig 5

Original Language Version

Environmental 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.

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.

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specications and component parts without prior notice.