Sealey BOOST120,BOOST140,BOOST160,BOOST180 Instruction Manual

INSTRUCTION MANUAL 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 DAMAGE
AND/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 item will give you years of trouble free performance if these instructions are
carefully followed and the product is correctly maintained.

1. SAFETY INSTRUCTIONS

1.1. IMPORTANT: Small battery chargers are supplied with plugs fitted. Boost chargers and starter/chargers however can draw more than

13Amps from the mains supply whilst cranking large engines. For this reason, boost chargers are not supplied with plugs fitted. We
recommend that for maximum performance your boost charger is plugged into a 30Amp supply and we further recommend that you
consult an electrician in order to fit an appropriate plug.
The following Electrical Safety Section must also be read and understood when using this equipment.

1.2. Electrical Safety

 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:

1.2.1. The Electricity at Work Act 1989 requires that all portable electrical appliances, if used on business premises, are tested by a
qualified electrician, 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 those appliances
and the safety of the appliance operators. If in any doubt about electrical safety, contact a qualified electrician.

1.2.3. Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.2.1. and 1.2.2.
and use a Portable Appliance Tester.

1.2.4. Ensure that cables are always protected against short circuit and overload.

1.2.5. Regularly inspect power supply cables and plugs for wear or damage and check all connections
to ensure that none are loose.

1.2.6. 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.

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

1.2.8. DO NOT pull the plug from the socket by the cable.

1.2.9. DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty item
repaired or replaced by a qualified electrician. When a BS 1363/A 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) and see right.
Subject to 1.1. above, the following details the fitting of a 13Amp plug since a 13Amp supply will be
adequate when charging and when starting small engines. No responsibility is accepted in the event
that the product is misused and/or used on a 13Amp supply when a 30Amp supply is required.
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 the wires as indicated above - DO NOT connect either wire to the earth terminal.

1.2.10. Products which require more than 13Amps are supplied without a plug. In this case you must contact a qualified electrician to ensure
that a suitably rated supply is available. We recommend that you discuss the installation of an industrial round pin plug and socket
with your electrician.

1.2.11. If an extension reel is used it should be fully unwound before connection. A reel with an RCD fitted is preferred since any appliance
plugged into it will be protected. The cable core section is important and should be at least 1.5mm², but to be absolutely sure that the
capacity of the reel is suitable for this product and for others which may be used in the other output sockets, we recommend the use
of 2.5mm² section cable.

1.3. General Safety

 WARNING! Disconnect the charger from the mains power before servicing or performing any maintenance.

 Disconnect the charger from the mains power before connecting to, or disconnecting from, the battery.
 Maintain the charger in good condition (use an authorised service agent only).

 WARNING! This starter/charger has components such as switches and relays which may cause sparks or arcs. When using this

machine in a garage or workshop, make sure it is in a safe location.

 Keep the charger clean for best and safest performance.

 WARNING! Ensure that there are no sources of flammable ignition near the work area i.e. naked flames, cigarettes, flame heaters,

etc., because the charging process produces explosive gases.

 WARNING! Ensure that the work area is well ventilated as the gases produced are flammable.

 Locate the starter/charger in a suitable work area and keep the area clean and tidy and free from unrelated materials. Ensure there is

adequate lighting.

 Wear approved safety eye protection (standard spectacles are not adequate).
 Remove ill fitting clothing. Remove ties, watches, rings and other loose jewellery and contain long hair.

FUSE RATING 13AMP

MODEL No's

BOOST120 BOOST140 BOOST160 BOOST180

Original Language Version

BOOST120, BOOST140, BOOST160, BOOST200 Issue: 1 - 15/05/12

MODEL: ...................BOOST120 ...... BOOST140 ......BOOST160 ...... BOOST180

Volts Input:.......................230V ............230V ............230V ............230V

Watts Input: ..................... 800W ...........900W...........1000W ..........1200W

Volts Output: ................... 12/24V ..........12/24V ...........12/24V ..........12/24V

Rated Charging Current: .............16A .............21A............. 26A .............36A

Maximum Charging Current: ..........20A .............25A............. 30A .............40A

Output Start Peak (EN): .......120A (70A) .......140A (80A) ......160A (110A) ......180A (120A)

Charge Capacity: ............. 20-250Ah ........20-280Ah ........ 25-320Ah ........30-400Ah

Polarity Protection: ........ Fuse (2 x 50A) ....Fuse (2 x 50A) ....Fuse (2 x 50A) ...Fuse (1 x 110A)

Fuse: . .....................120/802259 ......120/802259 .......120/802259 ....START360.F10

............................Pack of 20 .......Pack of 20 ........Pack of 20 ....... Pack of 10

 Read the vehicle handbook to check for any specific battery charging information.
 Disconnect the battery from the vehicle and move it to a safe, dry, level area for charging. If the battery can not be removed from the

vehicle refer to manufacturer ’s handbook.

 Check the electrolyte fluid level in the battery is above the plates. If not, add distilled water to cover them by 5-10mm. DO NOT touch

the battery fluid as it is corrosive.

 Clean the charger clamps and battery terminals, removing any oxidation before connecting the charger to the battery.
 Ensure that the correct polarity clamp is attached to the correct terminal of the battery. POSITIVE is indicated by (+) and may be red,

NEGATIVE is indicated by (-) and may be black. If there are no identifiable symbols, you can distinguish the NEGATIVE battery terminal
as the one which is connected from the battery directly to the vehicle body.

 Remove the battery electrolyte cover or caps to allow the gases produced by charging to escape.
 Keep children and unauthorised persons away from the work area.
 DO NOT attempt to charge a non-rechargeable battery.
 DO NOT use the charger for any purpose other than that for which it is designed.
 DO NOT allow untrained persons to operate the charger.
 DO NOT allow the charger terminal clamps to touch each other when the power is on or the charger fuse will blow. Remember that

gases are produced which may ignite if sparks occur.

 DO NOT place the charger inside the vehicle. Remove the battery to a safe distance for charging.
 DO NOT get the charger wet or use in damp or wet locations or areas where there is condensation.
 DO NOT operate the charger if it is damaged.
 DO NOT attempt to open or modify the charger.
 When not in use, unplug from the mains power supply and store in a safe, dry, child proof area.

 WARNING! Be vigilant and cautious during battery charging as the electrolyte is highly corrosive and the gases emitted are flammable

and harmful to health.

2. INTRODUCTION & SPECIFICATIONS

Original Language Version

BOOST120, BOOST140, BOOST160, BOOST200 Issue: 1 - 15/05/12

2.1 Combination units capable of both charging batteries and providing boost power to help start vehicles with at batteries. Models feature

easy-to-read ammeters and illuminated power switches. All models have dual output (12/24V) and circuitry is protected by a panel

mounted fuse. Model No. BOOST120 is suitable for eet operators running cars. Model No's BOOST140 & BOOST160 are suitable for
eet operators with both cars and van derivatives. Model No. BOOST180 is suitable for heavier garage use for engines up to 3ltr

capacity.

1.4. PERSONAL PRECAUTIONS

 Ensure that there is another person within hearing of your voice and close enough to come to your aid,

should a problem arise when working near a lead-acid battery.

 Wear safety eye protection and protective clothing. Avoid touching eyes while working near battery.
 Have fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
 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 to metal, which would cause severe burns.

 Ensure that hands, clothing (especially belts) are clear of fan blades and other moving or hot parts of the engine. Remove ties and

contain long hair.

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

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities or lack of
experience and knowledge, unless they have been given supervision or instruction concerning the use of the appliance by a person responsible
for their safety. Children should be supervised to ensure that they do not play with the appliance.

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 CHARGER.

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.

2.2