Sealey POWERSTART200 User manual

Thank you for purchasing this 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 DO SO MAY CAUSE DAMAGE
AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
2. SPECIFICATIONS
1. FEATURES
IMPORTANT: To reduce risk of battery explosion, follow these instructions and those published by the battery manufacturer and the
manufacturer of any equipment you intend to use in vicinity of the battery. Remember to review warning marks on all products and on engines.
3.1. PERSONAL PRECAUTIONS
!Ensure that there is another person within hearing distance and 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 near 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 melt or weld a ring, which would cause severe burns.
3.2. OTHER IMPORTANT SAFETY INSTRUCTIONS
!Familiarise yourself with the application, limitations and potential hazards of the unit.
!Keep the unit in good working condition. Take immediate action to repair or replace damaged parts.
!Only use recommended attachments and parts. To use unapproved items may be dangerous and will invalidate your warranty.
!The Powerstart must only be opened and checked by qualified service personnel. DO NOT disassemble for any reason.
!Keep children and unauthorised persons away from the work area.
!Keep work area clean and tidy and free from unrelated materials and ensure that there is adequate lighting.
!If the unit receives a sharp knock or blow, it must be checked by a qualified service agent before being used.
"DO NOT smoke or allow a spark or flame in the vicinity of the battery, engine or Powerstart.
"DO NOT drop any metal tool onto the battery as it may produce a spark or short circuit, which could cause an explosion.
Powerstart200/350/500 - 2 - 040907
3. SAFETY INSTRUCTIONS
# DANGER! RISK OF EXPLOSIVE GASES.
WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION.
FOR THIS REASON, IT IS VERY IMPORTANT TO READ AND FOLLOW THESE INSTRUCTIONS EXACTLY EACH TIME YOU USE THE POWERSTART.
INSTRUCTIONS FOR:
PORTABLE JUMP START UNITS
POWERSTART200, POWERSTART350, POWERSTART500
Powerstart200 Powerstart350 Powerstart500
Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . .Genesis . . . . . . . . . . . . . . .Hawker . . . . . . . . . . . . . . .Hawker
Start Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .200hp . . . . . . . . . . . . . . . .350hp . . . . . . . . . . . . . . . .500hp
DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12V . . . . . . . . . . . .12V . . .24V . . . . . . . . . . . .12V . . .24V
Peak Current . . . . . . . . . . . . . . . . . . . . . . . . . . .1600A . . . . . . . . . .3200A .1600A . . . . . . . . . .4000A .2000A
Cranking Current (20OC 5secs) . . . . . . . . . . . . . .680A . . . . . . . . . .1360A . .680A . . . . . . . . . .1500A . .750A
Cold Cranking Current (-18OC 30secs) . . . . . . . . .280A . . . . . . . . . . .560A . .280A . . . . . . . . . . .640A . .320A
Breakers (Charging Circuit Protection) . . .10A (Internal) . . . . .10A (External Reset) . . . . .10A (External Reset)
Charger Fuse . . . . . . . . . . . . . . . . . .630mA Antisurge . . . . . . . .630mA Antisurge . . . . . . . .630mA Antisurge
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10kg . . . . . . . . . . . . . . . . .19kg . . . . . . . . . . . . . . . . .17kg
Note: ‘Start Power’ indicates the size of engine that each Powerstart is capable of cranking.
GENERAL FEATURES
!Initial peak current: Powerstart200........1600 Amps
Powerstart350.......3200 Amps (12V)
Powerstart500.......4000 Amps (12V)
!Test switch and status meter.
!Automatic mains powered charger unit.
!Latest battery technology.
SAFETY FEATURES
!Polarity-indicating LEDs prevent cross-connection.
!The Powerstarts contain sealed lead-acid batteries. This means that the
Powerstart 200, 350 and 500 may be stored in any position without fear of leakage.
IMPORTANT: READ THE SAFETY INSTRUCTIONS BEFORE ATTEMPTING TO USE THE POWERSTART.
# WARNING! BEFORE CHARGING THIS UNIT, DISCONNECT THE OUTPUT LEADS FROM THE UNIT AS THEY WILL REMAIN “LIVE”
WHILE CHARGING.
# WARNING! NEVER CLAMP THE OUTPUT LEADS TO THE CARRY HANDLE AS THIS COULD RESULT IN SHORT CIRCUIT.

"DO NOT use the unit to recharge dry cell batteries (commonly used in home appliances). These batteries may burst and cause injury to
persons and/or damage to property.
"DO NOT charge or boost a frozen battery.
"DO NOT allow the power lead clamps to touch each other, or to contact the same piece of metal, as this will result in a damaging short circuit.
"DO NOT pull or carry the unit by its cables or wires 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 temperature may exceed 500C.
"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 will result in permanent damage.
"DO NOT cross-connect the power leads from the Powerstart to the battery. Ensure that positive is to positive and negative is to negative.
!The Powerstarts may be used under any weather conditions - rain, snow, hot or cold.
3.3. ELECTRICAL SAFETY IN RELATION TO BATTERY CHARGERS
# 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 an RCCB. If in any 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.
3.3.1. The Electricity at Work Act 1989 requires all portable electrical appliances, if used on business premises, to be tested by a qualified
electrician, using a Portable Appliance Tester (PAT), at least once a year.
3.3.2. 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 qualified electrician.
3.3.3. 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.
3.3.4. Ensure that cables are always protected against short circuit and overload.
3.3.5. Regularly inspect power supply cables and plugs for wear or damage and check all
connections to ensure that none is loose.
3.3.6. Important: Ensure that the voltage marked on the appliance matches the power supply
to be used and that the plug is fitted with the correct fuse - see fuse rating at right.
3.3.7. DO NOT pull or carry the appliance by the power cable.
3.3.8. DO NOT pull the plug from the socket by the cable.
3.3.9. DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty
item repaired or replaced by a qualified electrician. When an ASTA/BS approved UK
3 pin plug is damaged, cut the cable just above the plug and dispose of the plug safely.
Fit a new plug according to the following instructions (UK only).
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 that there are no bare wires, that all wires have been correctly connected, that the cable outer insulation
extends beyond the cable restraint and that the restraint is tight.
Double insulated products, which are always marked with this symbol , are fitted with live (brown) and neutral (blue) wires only.
To rewire, connect these two wires as indicated above - DO NOT connect either wire to the earth terminal.
FUSE RATING 3 AMP
Blue
Neutral
Wire
Yellow & Green
Earth Wire
Cable
Restraint
Brown
Live
Wire
4. CHARGING INSTRUCTIONS
WARNING! YOU MUST FOLLOW THE SAFETY INSTRUCTIONS
IMPORTANT! Only recharge Powerstarts with the AC charger provided. The charger is automatic and does not require the user
to monitor the progress of the charge. Futhermore, whenever the Powerstart is not in use it should be connected to the charger - failure
to do this will invalidate the warranty.
4.1. Reading the power level indicators
The charge level of the unit can be seen at any time by pressing the test button (fig. 1.A) and noting the meter (fig. 1.E) reading.
When the needle is in the green sector the unit is fully charged and is ready to be used.
The red sector indicates that immediate charging is required and the yellow sector
indicates that recharging is advisable.
4.2. Recharging
When new the unit should be charged before use until the charger display indicates ‘Full’.
#WARNING! Use the supplied charger, cable and connector. Unauthorised parts may
damage the unit and will invalidate the warranty.
Ensure that you strictly apply the safety instructions as stated in Section 3.
4.2.1. Ensure that the Powerstart control switch (fig. 1.D) is in the ‘Off’ position.
4.2.2. Plug the charger mains cable into a 230 volt supply. The green ‘On’ LED will illuminate.
4.2.3. Plug the charger cable into the charge input socket (fig. 1.B) of the unit. The unit will now
charge automatically and the charger LEDs will indicate the level of charge. When the
green ‘Full’ LED comes on, charging is complete but the charger should not be disconnected or switched off. Leave it connected to the
Powerstart to ensure that the unit is fully charged when next required.
4.2.4. To disconnect the charger from the Powerstart, first switch off the charger, then press and hold the latch immediately above the socket
and pull out the plug.
Important! If the ‘Fault’ LED on the charger illuminates, switch off the charger, disconnect it from the Powerstart and contact your Sealey dealer.
Note: The Powerstart charging circuits are protected against short circuit by thermal breakers. The breaker in the Powerstart200 has automatic reset
whilst those in the Powerstart350 and Powerstart500 (two in each - one per battery) have manual reset buttons on the front panel.
Powerstart200 shown
fig. 1
Powerstart200/350/500 - 2 - 040907

WARNING! YOU MUST FOLLOW SAFETY INSTRUCTIONS AND ENSURE THAT THE POWERSTART AND VEHICLE VOLTAGES ARE THE SAME.
5.1. Before use, press the test button to confirm that the Powerstart is charged (see 4.1.).
5.2. Apply the vehicle hand brake and select neutral gear (or ‘Park’ if automatic transmission). Turn ignition and
electrical accessories off.
5.3. Use in a well ventilated area and wear protective eye shields and clothing.
#WARNING! Do not allow the red and black clamps to touch each other once the leads are connected to the Powerstart. Ensure that
the correct clamps are placed on the correct battery terminals.
5.4. With the leads disconnected from the Powerstart attach the positive (RED +) clamp to the positive terminal on the vehicle battery.
Ensure that the terminal is clean.
Note: On vehicles with multiple batteries connect positive clamp to positive battery terminal which is connected to vehicle electrical system.
5.5. Attach the negative (BLACK -) clamp to the (ground) engine block or frame of the vehicle. Ensure that the cables are not in the path of
moving engine parts, such as the fan, and are away from the battery, carburettor/injection system, fuel lines etc.
5.6. Confirm that the green LED at the lead connector (fig. 2.1) is illuminated. If the red LED is illuminated then the clamps are cross-connected
and must be reversed.
5.7. With the Powerstart control switch (fig. 1.D) set to ‘Off’ plug the leads into the socket (fig. 1.C). Note that the connector will only fit the
socket one way round, to prevent cross-connection.
5.8. On models Powerstart 350 and Powerstart 500 turn the control switch (fig. 1.D) to select
12 or 24V to match the vehicle voltage. To select 24V the switch knob must be pulled out
and then turned.
On model Powerstart 200 turn the switch (fig. 1.D) to select 12V.
5.9. Make sure that no one is standing near the battery. When all is OK, start the engine.
5.10. Once the vehicle has started, turn the control switch (fig. 1.D) to ‘Off’ and then disconnect the leads
from the Powerstart.
5.11. Remove the lead clamps from the battery terminal and the earthing point.
IMPORTANT: If the vehicle does not start within six seconds, DO NOT continue cranking.
Let the Powerstart’s internal battery(ies) cool for three minutes before attempting to start the
vehicle again. Failure to do so may damage the unit.
5.12. After use, immediately recharge the Powerstart as described in 4.2.
# WARNING! BEFORE CHARGING THIS UNIT, DISCONNECT THE OUTPUT LEADS FROM THE UNIT AS THEY WILL REMAIN “LIVE”
WHILE CHARGING.
# WARNING! NEVER CLAMP THE OUTPUT LEADS TO THE CARRY HANDLE AS THIS COULD RESULT IN SHORT CIRCUIT.
#
WARNING! The warnings, cautions and instructions discussed in this manual cannot cover all possible conditions and
situations that may occur. It must be understood that common sense and caution are factors which cannot be built
into this product, but must be applied by the operator.
5. OPERATING INSTRUCTIONS
Declaration of Conformity We, the sole importer into the UK, declare that the product listed below is in conformity with the following standards and directives.
The construction file for this product is held by the Manufacturer and may be inspected, by a national authority,
upon request to Jack Sealey Ltd.
For Jack Sealey Ltd. Sole importer into the UK of Sealey Power Products.
4th September 2007
Signed by Mark Sweetman
QUESTION:
Can the Powerstart be recycled?
What is the ideal in-use storage temperature
of the Powerstart?
I have a regular battery charger, can I use it to
recharge the Powerstart?
Is the Powerstart fool proof?
Can the Powerstart battery(ies) be replaced?
ANSWER:
Yes, in accordance with local authority regulations.
Room temperature. The Roadstart will also operate at temperatures below zero,
however power will be lessened. Intense heat will activate self-discharge.
No, only the supplied charger can be used.
No. All jump starting instructions must be followed carefully.
Yes, through your Sealey dealer, but note: Batteries are not covered by warranty
as they are consumable items.
6. QUESTIONS & ANSWERS
7. DECLARATION OF CONFORMITY
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 equipment.
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 [e-mail] www.sealey.co.uk
01284 703534 Web
e-mail
Sole U.K. Distributor, Sealey Group,
Bury St. Edmunds, Suffolk.
fig. 2
Powerstart200/350/500 - 2 - 040907
AC/DC CHARGER
Model: PowerstartCP.
2006/95/EC Low Voltage Directive
2004/108/EC EMC Directive
93/68/EEC CE Marking Directive
2002/95/EC RoHS Directive
2002/96/EC WEEE Directive

Issue: 1
Issue Date: 030303
Item Part No. Description
1 SP.1 Power Control Switch - Powerstart200
1 SP.2 Power Control Switch, 12 & 24V - Powerstart350/500
3 SP.3 Thermal Fuse, 10A - Powerstart350/500
4 SP.4 Test Button c/w Wiring
- SP.5 Varistor
6 SP.6 4 Pin Charging Plug
7 SP.7 4 Pin Charging Socket
- SP.8 5A Fuse
- SP.9 5A Fuse Holder
10 SP.10 Reverse Polarity Indicator Unit
11 SP.11 500A Clamp, Pair
Item Part No. Description
12 SP.12 Battery Indicator Dial
15 SP.15 35mm2x2m Power Cable Complete - Powerstart200/350
15 SP.16 50mm2x2m Power Cable Complete - Powerstart500
21 SP.21 Snap Connector
50 SP.50 Casing - Powerstart200
50 SP.51 Casing - Powerstart350
50 SP.53 Casing - Powerstart500
- SP.55 Battery - Powerstart200/350
- SP.56 Battery - Powerstart500
58 PowerstartCP Charger
01284 757500 [e-mail] www.sealey.co.uk
01284 703534 Web
e-mail
Sole U.K. Distributor, Sealey Group,
Bury St. Edmunds, Suffolk.
Powerstart200
Powerstart350 & Powerstart500
PARTS LIST FOR:
PORTABLE JUMP START UNITS
POWERSTART200, POWERSTART350, POWERSTART500
Items are common to all three Powerstarts unless otherwise specified in the description.