Sealey BT91/7P User manual

INSTRUCTIONS FOR
PROFESSIONAL BATTERY DROP TESTER 6/12V -
POLARITY FREE
MODEL NO: BT91/7PF
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
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
BATTERY TESTER.
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.
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.
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.
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 tester as well as the potential hazards.Also refer to the vehicle manufacturer’s
hand book.
9IF IN ANY DOUBT CONSULT AN ELECTRICIAN.
9Ensure the tester is in good order and condition before use. If in any doubt do not use the unit and contact an electrician.
9Only use recommended attachments and parts. To use non-recommended items may be dangerous and will invalidate your warranty.
9Ensure the tester load switch is ‘Off’ before attaching/detaching the power clamps to/from the battery terminals.
9Keep tools and other items away from the engine and ensure you can see the battery and working parts of engine clearly.
9Confirm that the battery to be tested is 6 or 12 volt and not 24 volt before attaching clamps to battery terminals.
9If the tester 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 clamps.
9Keep children and unauthorised persons away from the working area.
8DO NOT dis-assemble the tester for any reason. The tester must only be checked by qualified service personnel.
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 pull the cables or clamps from the battery terminals.
8DO NOT use the tester in damp, or wet locations and DO NOT use within the vicinity of flammable liquids or gases.
9Ensure there is effective ventilation to prevent a build-up of explosive gases, and do not cover or obstruct tester ventilation louvres.
8DO NOT use the tester for a task for which it is not designed.
9When not in use, store the tester carefully in a safe, dry, childproof location.
8
DO NOT operate the load switch for more than 10 seconds at a time. (Failure to release the switch after 10 seconds may result in the
switch burning out and invalidating your warranty.)
2. INTRODUCTION
American pattern drop tester. Polarity protected cables - impossible to damage unit by misconnection. Load applied by internal switchgear - no
sparking! Suitable for 6 and 12Volt batteries. Applies load across cells and measures output on meter. Accurate indication of battery voltage, faulty
cell and short circuited cell.
BT91/7PF | Issue 2(L) 26/02/16
Original Language Version
© Jack Sealey Limited
Refer to
Instructions
Wear eye
Protection
Wear
Protective
Clothing
Warning:
Explosive
Material
Warning:
Corrosive
material
No open
ames
Wear
Protective
Gloves
Battery:
Ventilate area

3. OPERATION
WARNING! Ensure you read, understand and apply the safety and operational instructions before connecting the tester clamps to
the battery. Only when you are sure that you understand the procedures is it safe to proceed with the testing process.
3.1. Preparation
3.1.1. Checkbatterycasingforcracksorleakageandconrmthatitis6or12volts.
3.1.2. Clean battery terminals. If possible, check electrolyte levels and top up with distilled water as necessary.
3.2. Connection
WARNING! Ensure vehicle, or battery, is in a well ventilated area before starting test.
3.2.1. Attach positive (red) clamp to positive (+) battery terminal and negative (black) clamp to negative (-) terminal. Slightly twist clamps on
terminals two or three times to ensure a good electrical contact and a firm grip. Correct connection is indicated by the meter pointer (fig.1)
moving to the right, up the scale.
3.2.2. If the pointer moves to the left then the clamps should be reversed. If the pointer does not move at all there is either a bad connection or
the battery is completely dead.
3.2.3. Ensure that the clamp cables are clear of hot or moving engine parts, particularly if a starter or charging test is to be carried out.
Ventilation slots in tester casing should be unobstructed, meter should be easily visible and load switch accessible.
3.3. Battery load test
NOTE: ON THE FIRST LOAD TEST, SMOKE MAY BE EMITTED FROM THE LOUVRES IN THE TESTER CASING. THIS IS OIL
BURNING OFF THE LOAD COILS AND IS NORMAL.
3.3.1. Press load switch (fig.2) and hold until meter reading stabilizes, or for a maximum of 10 seconds. ( Failure to release the switch after 10
seconds may result in the switch burning out and your warranty being invalidated.) Note meter reading and then release load switch.
3.3.2. Compare meter reading with load test chart (3.4) to determine battery condition.
Notes:
a) For 12 volt batteries the green sector (fig.1.F) border is marked with nominal cranking current from 300 to 500
amps and stepped in 50 amp intervals.
Record this figure and compare with battery manufacturer’s quoted figure to give an indication of any deterioration.
b) Battery performance falls at low temperatures and quoted cranking amps should be reduced by 50 amps at 20°F(-7°C) and 100
amps at 0°F(-18°C).
3.4. Load Test Chart
3.5. Battery voltage/charge level
3.5.1. If the load test result indicates a battery fault, allow battery to stabilize for a few minutes and then read the open circuit voltage - meter reading
with load switch ‘Off’.
3.5.2. Compare the reading with the Voltage/Charge table below to get an estimation of the charge level.
Open Circuit Voltage Charge %
12 volt/6 volt battery
≤11.7/5.8 or lower 0
12.0/6.0 20
12.2/6.1 50
12.4/6.2 75
≥12.6/6.3 or higher 100
fig.1
NEGATIVE
CABLE
POSITIVE
CABLE
LOAD
SWITCH
fig.2
Load Test Result Battery Condition
OK - green Fig.1F - 12v
Fig.1B - 6v
Batterycapacityisgood.Mayormaynotbefullycharged.Checkelectrolytespecic
gravity to determine charge state. If not fully charged check charging system for fault
(paragraph 3.6) or electrical drain.
Bad or Weak - red or yellow,
but reading steady.
Fig.1D/E - 12v
Fig.1A/B - 6v
Battery capacity is unsatisfactory. Battery may be either: (1) defective or (2) partly
discharged.Checkelectrolytespecicgravity.Ifover1.225batteryisdefective.Ifunder
1.225rechargebatteryandretest.Ifcell-to-cellspecicgravityvariesbymorethan0.025a
celldefectmayexist.Ifchargingdoesnotbringspecicgravitytofullchargelevelbatteryis
sulphated or has lost active material.
Bad or weak - red or yellow,
but reading falling after 10
seconds on load.
Battery may be defective. Release load switch and note meter reaction. If voltage recovers
to 12 volts (6 volts for 6 volt battery) or more in a few seconds, then battery is probably
defective. If voltage recovers slowly battery may only be discharged. Check electrolyte
specicgravityandproceedasabove.
BT91/7PF | Issue 2(L) 26/02/16
Original Language Version
© Jack Sealey Limited

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.
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.
Sole UK Distributor, Sealey Group.
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk.
IP32 7AR
www.sealey.co.uk
[e-mail]
01284 757500
01284 703534
Web
3.5.3. The battery is considered charged at 75% or more. If it failed the load test with this charge it should be replaced. If the voltage indicates a
charge level below 75% then charge the battery and load test again. If it fails this second test replace it.
3.6. Charging system (12 volt)
3.6.1. Start engine and allow to reach normal operating temperature. Switch off all accessories.
3.6.2. Run engine at 1200 to 1500rpm and note meter reading, which should be in the green ‘OK’ sector (fig.1.H). DO NOT press the load switch.
3.6.3. Switch on head lights and heater fan (highest speed), meter reading should remain in the green ‘OK’ sector.
3.6.4. A reading in the red sector to the left (fig.1.G) indicates a fault in the charging system which will cause the battery to be under charged. A
reading in the red sector to the right (fig.1.I) indicates a fault which will cause the battery to be over charged.
Note: Although not marked on the meter scale the ‘OK’ range for a 6 volt charging system is 6.8 to 7.5 volts.
3.7. Starter motor (12 volt)
Note: This test requires that the battery is in good condition and is charged to at least 75% capacity.
3.7.1. Disable ignition system (remove fuse or similar) so that engine will not start.
3.7.2. Carry out a load test (para. 3.3.), if not already done, and note voltage reading.
3.7.3. Use the table on the meter (fig.1.J) to determine the equivalent minimum cranking voltage. Note that for engines of less than 3.25 litres
take the next higher figure. For example:
a) 3.5 litre engine - load test result 11.0 volts, gives min. cranking voltage of 9.7 volts.
b) 1.5 litre engine - load test result 11.0 volts, gives min. cranking voltage of 10.2 volts
3.7.4. Operate the starter motor and note the voltage during cranking.
3.7.5. A reading below the minimum cranking voltage indicates that the starter motor is taking excessive current. This may be due to poor
connections, to a faulty motor or to the battery being too small for vehicle.
3.7.6. After test reinstate ignition system.
Note: For a 6 volt system test as above and note load test voltage. Double this value and determine equivalent min. cranking voltage as in 3.7.3.
Halve the figure to give min. cranking voltage for the 6 volt system and then proceed from 3.7.4.
BT91/7PF | Issue 2(L) 26/02/16
Original Language Version
© Jack Sealey Limited
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.
When the product becomes completely unserviceable and requires disposal, drain off any fluids (if applicable)
into approved containers and dispose of the product and the fluids according to local regulations.
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.