Sealey RS1.V4 User manual

INSTRUCTIONS FOR:
ROADSTART UNITS
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: BEFORE USING THIS PRODUCT, PLEASE READ THE INSTRUCTIONS CAREFULLY. MAKE CAREFUL NOTE OF SAFETY INSTRUCTIONS, WARNINGS
AND CAUTIONS. THIS PRODUCT SHOULD ONLY BE USED FOR ITS INTENDED PURPOSE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY CAUSE DAMAGE
AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
IMPORTANT: To reduce the risk of a battery explosion, follow these
instructions and those published by the battery manufacturer 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.
1.1 PERSONAL PRECAUTIONS
Ensure there is another person within hearing range, or close
enough to come to your aid should a problem arise, when
working near a lead-acid battery.
Have fresh water and soap nearby in case battery acid contacts
skin, clothing or eyes.
Wear safety eye protection and protective clothing. Avoid
touching eyes while working with a battery.
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 the like to
metal, which may cause severe burns.
1.2 IMPORTANT SAFETY INSTRUCTIONS
Familiarise yourself with the applications, limitations and potential
hazards of the RoadStart.
Keep the unit in good working order and condition. Replace
damaged parts immediately.
Use only recommended parts. To use unapproved parts may be
dangerous and will invalidate your warranty.
The RoadStart must only be opened and checked by qualified
service personnel. DO NOT disassemble the unit for any reason.
Keep children and unauthorised persons away from the work area.
Keep work area clean and tidy and free from unrelated materials.
Ensure that there is adequate lighting.
1. SAFETY INSTRUCTIONS
WARNING! RISK OF EXPLOSIVE GASES. Working in the vicinity of a lead acid battery is dangerous because they can
generate explosive gases. It is important to remember that batteries generate explosive gases during normal operation.
WARNING! This equipment contains a sealed, non-spillable lead acid battery. This must be disposed of in accordance with
local regulations.
RS1.V4 RS102.V3 RS103.V2 RS104.V2 RS105.V2
If the RoadStart receives a sharp knock or blow, it must be
checked by a qualified service agent before being used.
When not in use re-charge every two months.
DO NOT smoke or allow a spark, or flame in the vicinity of the
battery or engine.
DO NOT drop any metal item onto the battery as it may spark
or short circuit the battery, which could cause an explosion.
DO NOT use RoadStart to recharge dry cell batteries that are
commonly used with home appliances. These batteries may
explode and cause personal injury and damage to property.
DO NOT charge or boost a frozen battery.
DO NOT use attachments other than those recommended. To
do so may risk damage to the unit and other equipment and possible
personal injury.
DO NOT pull or carry the unit by its cables and do not pull the
negative and positive clamps from the battery terminals.
DO NOT operate in vicinity of flammable liquids or gases.
DO NOT recharge the unit with plugs, cables or attachments
that are damaged. Replace such items immediately.
DO NOT use this product to perform a task for which it is not
designed.
DO NOT store the unit in damp or wet locations or where the
temperature may exceed 50°C.
DO NOT submerge the unit in water.
DO NOT use whilst under the influence of drugs, alcohol or
intoxicating medication.
DO NOT leave the unit in a totally discharged state for an
extended period of time as this may result in permanent damage.
DO NOT cross-connect the power leads from the RoadStart to
the battery. Ensure that positive is to positive and negative is to
negative.
Ensure that the unit is fully charged before storage.
IMPORTANT: USE OF RS105:
IMPORTANT: Be sure to check the voltage switch of the RS105 is turned to the correct voltage before connecting the cables to the vehicle.
IN THE EVENT OF CONNECTION TO 24VOLT SYSTEM WITH THE SELECTION IN THE 12VOLT POSITION:
DO NOT• TOUCH THE ROTARY SWITCH.
DISCONNECT• THE BATTERY AND LEAVE THE ROADSTART UNIT TO REST FOR AT LEAST ½ AN HOUR.
DANGER OF EXPLOSION IF THESE INSTRUCTIONS ARE NOT OBSERVED.
Original Language Version RS1.V4, RS102.V3, RS103.V2, RS104.V2, RS105.V2 Issue: 5 - 06/01/12
IMPORTANT WARRANTY INFORMATION: KEEP YOUR ROADSTART HEALTHY
Read and understand the general safety and operating instructions before use. The following information is intended to help you
keep the product in top working order.
NOTE – The battery in this unit is a consumable item and its ability to accept charge will reduce over time. We will warranty it
against mechanical and electrical defect for a period of one year - this does not cover fair wear and tear.
If the battery is not properly charged before first use, or regularly conditioned, its capacity will diminish. Under these circumstances we will
not replace the battery even if it is less than one year old.
You can help prolong the lifecycle of the battery by following a few simple guidelines.
Plug in your new Roadstart to the mains transformer and make an INITIAL charge lasting 38 hours.•
Ensure the unit is fully charged before storage.•
• DO NOT leave the Roadstart for longer than 2 months without putting it on charge.
• DO NOT attempt to start a vehicle when the Roadstart battery voltage is reduced to less than 7Volts.
• DO NOT drop or roughly handle the Roadstart – this will break or disjoin the battery terminals rendering the battery useless and the
warranty void.
• DO NOT use any other charger, other than the one supplied, to recharge the battery.

2. SPECIFICATION & FEATURES
2.1 Specification
Models .............................RS1.V4 ......RS102.V3
Cold Cranking amps.............300A ..............600A
Peak Amps .........................1000A ............1600A
Voltage....................................12V ................24V
Auxiliary Output ......................12V ................12V
Cable and Clamp Length ..0.5mtr. ............1.0mtr
Weight ................................. 8.2kg ................ 9kg
Models .........................RS103.V2 ......RS104.V2 ....... RS105.V2
Cold Cranking amps...........1000A ..............500A...... 1000/500A
Peak Amps .........................3200A ............1600A.... 3200/1600A
Voltage....................................12V ................24V ............ 12/24V
Auxiliary Output ......................12V ................12V ................. 12V
Cable and Clamp Length ..1.8mtr. ...........1.8mtr. ............ 1.8mtr.
Weight ............................... 16.9kg ........... 17.2kg .............17.5kg
2.2 Product Features
(Key to figs. 1,2 & 3 )
1) POSITIVE BATTERY CLAMP
2) FLEXIBLE HEAVY DUTY COPPER CABLE
3) CHARGING POINT
4) 12VDC OUTPUT/CHARGING SOCKET
5) TEST BUTTON
6) AMBER LED CHARGING INDICATOR
7) RED POWER LEVEL LED INDICATORS
8) GREEN FULLY CHARGED LED INDICATOR
9) FLEXIBLE HEAVY DUTY COPPER CABLE
10) NEGATIVE BATTERY CLAMP
11) SAFETY STORAGE HOLSTER
12) HEAVY DUTY PLASTIC CASE
13) SAFETY STORAGE HOLSTER
14) 12VOLT SYSTEM RECHARGE INDICATOR
15) 24VOLT SYSTEM RECHARGE INDICATOR
16) 3 POSITION SELECTOR SWITCH 12V/OFF/24V
RS1.V4
RS102.V3
RS103.V2
RS104.V2
RS105.V2
g.3
g.2
g.1
Original Language Version RS1.V4, RS102.V3, RS103.V2, RS104.V2, RS105.V2 Issue: 3 - 04/11/09
1.3 ELECTRICAL SAFETY (with respect to mains chargers)
WARNING! It is the user’s responsibility to check the following:
You must check the AC adaptor to ensure that it is safe before
using. You must inspect the power supply lead, 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 plug into an electrical supply not protected by an RCCB. If
in doubt consult a qualified electrician. You can obtain a
Residual Current Device through your Sealey dealer.
You must read and understand instructions concerning
electrical safety.
1.3.1 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.
1.3.2 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.
1.3.3 DO ensure that the insulation on all cables and the product itself
is safe before connecting to the mains power supply.
1.3.4 DO ensure that cables are always protected against short circuit
and overload.
1.3.5 DO regularly inspect power supply, leads, plugs for wear and
damage and power connections to ensure that none is loose.
1.3.6 DO check product voltage is the same as power supply to be
used and check that all fused plugs are fitted with the correct
capacity fuses.

3. CHARGING INSTRUCTIONS
WARNING! YOU MUST FOLLOW
THE SAFETY INSTRUCTIONS
3.1 Charging methods for Roadstart mobile power systems
3.1.1 The first method is to use the AC chargers provided for each
unit. This is the preferred method as it is automatic and does
not require the user to monitor the progress of the charge.
Furthermore whenever the unit is not in use it can safely be left
connected to the charger.
3.1.2 The second method is to charge the units from the cigarette
lighter socket of a vehicle when the engine is running. This
method is not automatic and could result in the unit being
overcharged if the user fails to monitor the charge and
disconnect the power source when full charge is reached.
Overcharging could result in permanent damage to the unit.
3.2 Reading the power level indicators (See figs.4 & 6)
The charge level of each unit can be seen at any time by
pressing the test button and noting the number of red power
level lights that are illuminated. When all three power level
lights are illuminated the unit is fully charged and is ready to be
used. If only two red lights are illuminated the unit is in a 50%
charge status and could be used to operate most 12 volt
accessories. If the unit is required for starting it should be
charged until all three red lights are illuminated. If there is only
one red light illuminated the unit is low and must be recharged.
If the amber charging light begins to flash on 12V models this
means that the battery voltage has dropped to 7.25V or below
and the unit will not work until it is fully recharged. An amber
light flashing on the RS104.V2 (24V) indicates that the voltage
has dropped to 14.5V or below and the unit must be recharged.
3.3 Initial Charging Procedure
3.3.1 Before first use, these roadstart units should be charged for a
minimum of 72 hours.
WARNING! Use supplied adaptor, cables and connectors.
Unauthorised parts may damage the unit and will invalidate the
warranty. Ensure you strictly apply the safety regulations as
stated in Section 1.
3.4 To recharge with the AC charging adaptor
Only charge with the adaptor supplied with your specific
model. See below. The adaptors are not interchangeable.
3.4.1 RS1.V4 & RS102.V3 Use the charger supplied, see fig.7.
Plug the AC charger cable into the charge input socket of the
unit. This socket is situated on the back of the unit at the top
of the label. See fig.1-3.
3.4.2 RS103.V2 Use the charger supplied, see fig.7. The adaptor
charging jack is inserted into the charge port, located beneath
the LED power indicators. See fig.6.
3.4.3 RS104.V2 When recharging this 24V version a 24V rated
mains adaptor is to be used. Refer to Fig. 7. The adaptor
charging jack is inserted into the charge port, located beneath
the LED power indicators. See fig.6.
3.4.4 RS105.V2 IMPORTANT: When recharging this 12V/24V
version the VOLTAGE switch must be set at the 12V position
and the 12V mains adaptor used. Refer to figs 6 & 7.
3.4.5 Ensure the power clamps are in the appropriate holsters.
3.4.6 Plug the charger itself into any 230 Volt AC wall outlet. The
amber ‘Charging’ indicator will illuminate, see figs.4 & 6.The
unit will now charge automatically and the power level lights will
indicate the level of charge. When the green ‘Charged’ LED
comes on (see figs.4 & 6) charge for a further 3 to 6 hours to
achieve full capacity. When not in use these Roadstart can be
left connected to the charger.
3.4.7 To recharging with the 2-pin European adapter.
When using the Roadstarts in a European country remove
the 3-pin UK plug by pushing the button on the adapter
and turning anti-clockwise, replace with the 2-pin plug,
placing it on the transformer and turning clockwise until
fully home. See fig.7.
3.5 To recharge with the DC charging cable
Note: This method of charging is not automatically
protected against overcharging and must be constantly
monitored by the user as described below. IMPORTANT:
Always ensure that the vehicle voltage matches the
voltage of the Roadstart unit.
g.6
g.4
g.5
DC CHARGING
CABLE
ALL
MODELS
g.7
Original Language Version RS1.V4, RS102.V3, RS103.V2, RS104.V2, RS105.V2 Issue: 5 - 06/01/12
3.5.1 Ensure that the power clamps are in the appropriate holsters.
3.5.2 With the vehicle engine running plug the DC charging cable
into the charge input socket on the unit (Refer to 4 in figs.1,2 &3)
and then the other end into the vehicle cigarette lighter socket.
The unit will be charged by the alternator. It will be necessary
to press the test button once every hour to monitor the level of
charge. When all of the red lights are illuminated plus the green
‘charged’ light continue to charge for another 1 to 2 hours and
then disconnect the unit from the vehicle lighter socket to avoid
overcharging which could damage the unit.
Note: If the the amber charging light begins to flash or the
battery becomes completely flat, then a 72 hour charge will be
necessary using the AC charger.

WARNING! YOU MUST FOLLOW THE SAFETY INSTRUCTIONS
4.1 Preparation and precautions
WARNING! ENSURE THAT THE ROADSTART AND VEHICLE
VOLTAGES ARE THE SAME.
4.1.1 Apply the vehicle hand brake and place in neutral gear (or
“Park” if automatic transmission).
4.1.2 Turn ignition and electrical accessories off. NOTE: Some
vehicle ignition systems must be turned to “Accessory” to
activate the cigarette lighter socket.
4.1.3 Use in a well ventilated area and wear protective eye shields
and clothing.
4.1.4 NOTE: A defective battery may not accept a charge from the
portable power source.
WARNING! Do not allow the red and black clamps to touch
each other. Ensure that the correct clamps are placed on the
correct battery terminals.
4.2 Boosting vehicle battery
4.2.1 Plug one end of the charging lead into the RoadStart unit.
4.2.2 Plug the other end into the vehicle cigarette lighter socket.
4.2.3 Allow the vehicle battery to charge for thirty minutes.
4.2.4 Remove the charging lead and start the vehicle.
4.3 Emergency Jump Starter
NOTE: For optimum performance, the unit should not be stored
below 10°C when using the unit as a jump starter.
IMPORTANT: The unit will only jump start a vehicle if the
vehicle battery voltage is greater than 7V. If the battery is
delivering less than 7V, refer to Section 4.2 and follow the
instructions to boost the vehicle battery.
4.3.1 Turn off the vehicle ignition.
4.3.2 Attach the RED (positive +) clamp to the positive terminal of the
battery.
Note: On vehicles with multiple batteries connect positive clamp
to positive battery terminal which is connected to vehicle
electrical system.
4.3.3 Attach the BLACK (negative -) clamp to the vehicle chassis.
4.3.4 Ensure that all cables are clear of moving belts and rotating fans.
4.3.5 Maintain a safe distance from the battery whilst jump starting.
4.3.6 Turn on the ignition to start the vehicle.
NOTE: If the vehicle does not start after 6 seconds, allow the
RoadStart unit to cool for 3 minutes, before attempting to jump
start the vehicle again. If this is not done, the unit could sustain
damage.
4.3.7 When the vehicle has started, disconnect the BLACK
 (negative-)clamprstfromthevehiclechassis.
4.3.8 Remove the RED (positive +) clamp from the battery terminal.
4.3.9 Return the clamps to the side storage pockets.
4. OPERATION
5. TROUBLESHOOTING
THE PROBLEM THE SOLUTION
Unit works well but no
change in light status
when the adaptor is
connected to the
RoadStart unit.
Possible defective battery or faulty
breaker. Use a device such as a light
with a dc plug to check that it works. If
the light works, the power source
breaker is serviceable and the battery is
defective.
When the adaptor is
plugged into the
RoadStart unit all LEDs
light. When the adaptor
is unplugged and the
test button depressed,
no LEDs light.
Roadstart unit battery defective which
could have been caused by intense use
without a cool-down period.
Roadstart unit is fully
charged but delivers no
power.
Check where the wires meets the jaw on
the unit clamps. Ensure they are well
crimped.
If the unit has a power switch, ensure
that it is in the ON position.
When trying to use an
accessory via the dc
outlet, a clicking sound
is heard inside the
RoadStart unit.
The accessory is drawing too much
current, resulting in the internal circuit
breaker switching between ON and OFF.
IMPORTANT: USE OF RS105:
IMPORTANT: Be sure to check the voltage switch of the RS105
is turned to the correct voltage before connecting the cables to the
vehicle.
IN THE EVENT OF CONNECTION TO 24VOLT SYSTEM
WITH THE SELECTION IN THE 12VOLT POSITION:
DO NOT• TOUCH THE ROTARY SWITCH.
DISCONNECT• THE BATTERY AND LEAVE THE
ROADSTART UNIT TO REST FOR AT LEAST ½ AN
HOUR.
DANGER OF EXPLOSION IF THESE INSTRUCTIONS
ARE NOT OBSERVED.
4.4 Alternative Vehicle Power Supply
4.4.1 When a vehicle battery is disconnected, the memory systems in
radios, electronic ignition systems and alarms are frequently lost.
4.4.2 When replacing a battery the RoadStart unit can be used as an
alternative power supply by connecting the unit dc extension
lead into the cigarette lighter socket.
4.4.3 This will prevent loss of memory in the systems outlined in
Paragraph 4.3.1.
WARNING! The positive battery cable will be live and MUST be
insulated (e.g. in a heavy duty plastic bag).
4.5 Multipurpose Power Supply
4.5.1 These RoadStart units can be used as a multipurpose power
supply to power up any equipment with a built-in 12Vdc male
adaptor.
4.5.2 The dc outlet on the roadstart units is equipped with overload
protection.
4.5.3 The twin battery models RS103.V2, RS104.V2 & RS105.V2,
when used with an inverter, can operate equipment usually
powered by either 110VAC or 230VAC.
NOTE: The inverter power draw must not exceed 300 Watts.
4.6 RoadStart Battery Test
4.6.1 Fully charge the RoadStart unit battery so that all RED LEDs light.
4.6.2 Connect a 100A battery load tester across RoadStart unit battery.
4.6.3 The load tester voltmeter should read 9V or higher for a period
of 6 seconds.
4.6.4 Disconnect the battery load tester.
Original Language Version RS1.V4, RS102.V3, RS103.V2, RS104.V2, RS105.V2 Issue: 5 - 06/01/12

6. QUESTIONS&ANSWERS
QUESTION ANSWER
How many jump
starts can a fully
charged RoadStart
do before needing to
be recharged?
Between 1 and 20 depending upon
operating factors such as temperature,
general condition of the vehicle, engine type
and size.
Can the RoadStart
be recycled?
Yes, in accordance with national and local
authority regulations.
What is the ideal
in-use storage
temperature
of the RoadStart?
Room temperature. The RoadStart will also
operate at temperatures below zero, its
power however will be lessened. Intense
heat will activate self-discharge.
I have a regular 10
amp battery charger,
can I use it to
recharge the
RoadStart?
No. Only the supplied adaptor and charger
can be used.
Is the RoadStart fool
proof?
No. All jump starting instructions must be
followed carefully.
Can I replace the
internal batteries?
Yes, but note that the batteries are not
covered by warranty as they are
consumable items
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 RS1.V4, RS102.V3, RS103.V2, RS104.V2, RS105.V2 Issue: 5 - 06/01/12
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.
Contact your local solid waste authority for recycling
information.
Battery Removal
Removal
1. Place the RoadStart unit front side down.
2. Remove the 14 screws holding the casing together and
lift off the back half of the unit.
3. Disconnect the wires from the two battery terminals,
taking care to avoid accidental arcing of the terminals.
4. Lift the batteries out of the front half of the casing.
Disposal
1. Take the battery to a recycling centre that handles
sealed, lead-acid batteries.
2. If there is no recycling centre in the area, contact the
local environmental agency for disposal instructions.
Dispose of batteries according to local authority
guidelines.
Under the Waste Batteries and Accumulators Regulations 2009,
Jack Sealey Ltd are required to inform potential purchasers of
products containing batteries (as defined within these regulations),
that they are registered with Valpak’s registered compliance
scheme.
Jack Sealey Ltd’s Batteries Producer Registration Number (BPRN)
is BPRN00705