Sealey SERVICE160 - User Manual

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INSTRUCTIONS FOR:

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.

Model Nos: SERVICE160, 160+, 200, 250. SUPERSTART220, 310, 320/1, 410,

420/1, 520/1, 620/1. POWERSTART300, 400.

1. SAFETY INSTRUCTIONS

1.2. ELECTRICAL SAFETY.

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.

Connect the BLUE neutral wire to the neutral terminal N.

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

1.1. IMPORTANT: 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 your starter/charger is 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.

1.3. PERSONAL PRECAUTIONS

3 Ensure 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.

3 Wear safety eye protection and protective clothing. Avoid touching eyes while working near battery.

3 Have fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

3 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.

3 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.

3 Ensure hands, clothing (especially belts) are clear of fan blades and other moving or hot parts of engine, remove ties and contain long hair

7 DO NOT smoke or allow a spark or flame in the vicinity of battery or engine.

1.4. GENERAL SAFETY INSTRUCTIONS

3 Familiarise 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.

3 Ensure the starter/charger is in good order and condition before use. If in any doubt do not use the unit and contact an electrician.

3 Only use recommended attachments and parts. To use non-recommended items may be dangerous and will invalidate your warranty.

3 Use the starter/charger in the horizontal position only and ensure it is placed on a stable surface which will adequately support the weight.

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.

STARTER/CHARGERS (Service, Superstart and Powerstart models) - 0051 - (2) - 120301

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Summary

SAFETY INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS

Key safety guidelines for starter/charger use and operational requirements.

ELECTRICAL SAFETY

Comprehensive electrical safety checks and recommendations for user protection.

PERSONAL PRECAUTIONS

Essential safety measures for users when working near batteries and engines.

GENERAL SAFETY INSTRUCTIONS

General advice on safe usage, maintenance, and positioning of starter/chargers.

SPECIFICATIONS

Model Specifications

Detailed technical specifications for various Sealey starter/charger models.

OPERATING INSTRUCTIONS

PREPARATION

Steps for preparing the starter/charger and battery before operation.

CONNECTING CHARGER TO BATTERY

Step-by-step guide for safely connecting the charger to battery terminals.

CHARGING THE BATTERY

Instructions for connecting to mains power and charging the battery.

RAPID CHARGE

Procedure for utilizing the sixty-minute timer for rapid charging.

STARTING A VEHICLE WITH A FLAT BATTERY

Guidance on using the starter function for vehicles with discharged batteries.

FUSES

Fuse Function and Replacement

Explanation of fuses, reasons for blowing, and proper replacement procedures.

Summary

SAFETY INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS

Key safety guidelines for starter/charger use and operational requirements.

ELECTRICAL SAFETY

Comprehensive electrical safety checks and recommendations for user protection.

PERSONAL PRECAUTIONS

Essential safety measures for users when working near batteries and engines.

GENERAL SAFETY INSTRUCTIONS

General advice on safe usage, maintenance, and positioning of starter/chargers.

SPECIFICATIONS

Model Specifications

Detailed technical specifications for various Sealey starter/charger models.

OPERATING INSTRUCTIONS

PREPARATION

Steps for preparing the starter/charger and battery before operation.

CONNECTING CHARGER TO BATTERY

Step-by-step guide for safely connecting the charger to battery terminals.

CHARGING THE BATTERY

Instructions for connecting to mains power and charging the battery.

RAPID CHARGE

Procedure for utilizing the sixty-minute timer for rapid charging.

STARTING A VEHICLE WITH A FLAT BATTERY

Guidance on using the starter function for vehicles with discharged batteries.

FUSES

Fuse Function and Replacement

Explanation of fuses, reasons for blowing, and proper replacement procedures.

This document describes the Sealey Power Products Starter/Chargers, including models SERVICE160, 160+, 200, 250, SUPERSTART220, 310, 320/1, 410, 420/1, 520/1, 620/1, POWERSTART300, and 400. These devices are designed for charging batteries and providing a starting boost for vehicles.

Function Description:

The Sealey Starter/Chargers are versatile units capable of both charging lead-acid batteries and assisting in starting vehicles with flat batteries. They provide various charging rates (low, medium, high) and can operate at either 12V or 24V, depending on the model. Some models feature a rapid charge facility with a sixty-minute timer. The device monitors the charging current via an ammeter, which initially shows a high rate and gradually decreases as the battery charges. Once fully charged, the ammeter reading approaches "0," and the electrolyte may begin to gas. For starting a vehicle, the unit delivers a sufficient output to crank appropriate-sized engines. Safety features include an internal fuse system that protects against overload, short circuits, and prolonged starting attempts.

Important Technical Specifications:

The specifications vary by model, covering output charge peak (EN) for both 12V and 24V, output start peak (EN) for 12V and 24V, input charge and start currents, input voltage (230V), and output voltage (12V or 12V/24V). Each model also specifies the fuse reference and quantity.

For example:

SERVICE160: Output 12V Charge Peak (EN) 45A (30A), Output 12V Start Peak (EN) 160A (140A), Input-Charge 2.5A, Input-Start 12A, Output 12V.
SUPERSTART220: Output 12V/24V Charge Peak (EN) 40A (25A), Output 12V/24V Start Peak (EN) 200A (140A), Input-Charge 3A/6A, Input-Start 15A, Output 12V/24V.
POWERSTART400: Output 12V/24V Charge Peak (EN) 75A (50A), Output 12V/24V Start Peak (EN) 450A (300A), Input-Charge 4A, Input-Start 22A, Output 12V/24V.

All models operate on a 230V input. Fuse types and quantities are critical for maintenance, with specific references provided for each model (e.g., 120/122438 (2), 120/802260).

Usage Features:

Electrical Safety: Users are responsible for checking all electrical equipment, leads, plugs, and connections for wear and damage. An RCCB (Residual Current Circuit Breaker) or RCD (Residual Current Device) is recommended. The units are not supplied with a fitted plug for starting large engines, requiring a 30 amp electrical supply and professional installation. For charging and starting small vehicles, a 13 amp plug can be fitted, with wiring instructions provided (Green/Yellow to Earth 'E', Brown to Live 'L', Blue to Neutral 'N').
Personal Precautions: Always ensure another person is within hearing range when working near a lead-acid battery. Wear safety eye protection and protective clothing. Have fresh water and soap available for acid contact. Remove personal metallic items. Avoid smoking or sparks near the battery.
Preparation for Charging: Before connecting, ensure the charger is unplugged from the mains. If the battery has caps, remove them and check fluid levels, topping up with distilled water if necessary. Clean battery terminals. Set the charger voltage to match the battery (12V or 24V). Connect the positive (red) lead to the battery's positive terminal and the negative (black) lead to the battery's negative terminal.
Charging Process: Connect the charger to the mains, select the appropriate charge rate (low, medium, high). Monitor the ammeter; it will decrease as the battery charges. Stop charging when the ammeter reads near "0" and the electrolyte begins to gas to prevent damage. Disconnect from mains, then disconnect clamps, clean, and store.
Rapid Charge: Some models have a sixty-minute timer for rapid charging. Select the 'Hare' symbol and set the timer (max 60 minutes). The charger will automatically switch off.
Starting a Vehicle: Ensure the charger is disconnected from mains. Set the output voltage to match the vehicle battery. Clean charger clamps and battery terminals. Connect positive to positive, negative to negative. Plug the charger into mains, select a low charge rate, and charge for 2-3 minutes. Turn the charger switch to 'Start' for about 25 seconds, then crank the engine for a MAXIMUM of 10 seconds. If it doesn't start after two attempts, discontinue and investigate vehicle faults. Once the vehicle is running, switch off the charger, unplug from mains, and disconnect terminals.

Maintenance Features:

General Safety: Familiarize yourself with the product's application, limitations, and hazards. Ensure the starter/charger is in good order and condition. Use only recommended attachments and parts. Operate on a stable, horizontal surface.
Fuse Replacement: The starter/charger is equipped with safety fuses that will blow under overload, short circuit, or prolonged starting attempts. If a fuse blows, turn off the unit, disconnect from mains, allow it to cool, identify and correct the reason for failure, and replace the fuse with an identical Sealey replacement fuse. Do not use copper bridges or similar. It is recommended to keep 2 or 3 spare fuses. Using an incorrect fuse will invalidate the warranty.
Storage: When not in use, store the starter/charger carefully in a safe, dry, childproof location.
Inspection: Regularly inspect power supply leads, plugs, and all electrical connections for wear and damage. Ensure insulation on all cables and the product itself is safe. If the unit receives a sharp knock or blow, it must be checked by a qualified service agent.
Battery Condition: Regularly check battery electrolyte levels and specific density using a hydrometer to determine charging status (1.28 = Fully charged, 1.21 = Half charged, 1.14 = Fully discharged). Always handle battery fluid with caution as it is highly corrosive sulphuric acid.