INSTRUCTIONS FOR:
BATTERY SUPPORT UNIT & CHARGER
12V-25A 24V-12.5A
MODEL No: BSCU25.V2
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these instructions
and maintained properly, 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.
Refer to
instructions
Keep away from
rain
Wear eye
protection
Wear protective
gloves
Electrical
shock
hazard
Warning
corrosive
substance
Warning:
explosive
material
Keep away
from sources of
ignition
Use in well
ventilated areas
1. SAFETY
1.1. Electrical Safety
WARNING! It is the user’s responsibility to check the following:
Check all electrical equipment and appliances to ensure that they are safe before using. Inspect power supply leads, plugs and
all electrical connections for wear and damage. Sealey recommend that an RCD (Residual Current Device) is used with all electrical
products.
If the charger is used in the course of business duties, it must be maintained in a safe condition and routinely PAT (Portable
Appliance Test) tested.
Electrical safety information, it is important that the following information is read and understood.
Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply.
1.1.1. Inspect power supply cables and plugs regularly for wear or damage and check all connections to ensure that they are secure.
1.1.2. Ensure that the voltage rating on the appliance suits the power supply to be used and that the plug is tted with the correct fuse - see
fuse rating in these instructions.
8 DO NOT pull or carry the appliance by the power cable.
8 DO NOT pull the plug from the socket by the cable. Remove the plug from the socket by maintaining a rm grip on the plug.
8 DO NOT use worn or damaged cables, plugs or connectors. Ensure that any faulty item is repaired or replaced immediately by a
qualied electrician.
1.1.3. This product is tted with a BS1363/A 13 Amp 3 pin plug.
1.1.4. If the cable or plug is damaged during use, switch the electricity supply and remove from use.
1.1.5. Replace a damaged plug with a BS1363/A 13 Amp 3 pin plug. If in doubt contact a qualied electrician.
1.1.6. Class II products are wired with live (brown) and neutral (blue) only and are marked with the Class II symbol:
A) Connect the BROWN live wire to the live terminal ‘L’.
B) Connect the BLUE neutral wire to the neutral terminal ‘N’.
C) After wiring, check that there are no bare wires and ensure that all wires have been correctly
connected.
1.1.7. Ensure that the cable outer sheath extends inside the cable restraint and that the restraint is tight.
8 DO NOT connect either wire to the earth terminal.
Sealey recommend that repairs are carried out by a qualied electrician.
▲ DANGER! BE AWARE, LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION.
FOR THIS REASON, IT VERY IMPORTANT TO READ AND FOLLOW THESE INSTRUCTIONS CAREFULLY, EACH TIME YOU USE
THE CHARGING EQUIPMENT.
1.1.8. 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. Review warning marks on all products and on engines.
WARNING! Modern vehicles contain extensive electronic systems.
Check with the vehicle Manufacturer for any specic instructions regarding the use of this type of equipment on each vehicle.
No liability will be accepted for damage / injury, where this product is not used in accordance with all instructions.
© Jack Sealey Limited
Original Language Version
Recommended fuse
rating: 13Amp
BSCU25.V2 Issue:2 (H,F) - 27/03/18
1.2. Personal Precautions
9 Ensure 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.
9 Wear safety eye protection and protective clothing. Avoid touching eyes while working near battery.
9 Have fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
9 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.
9 Remove 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.
9 Ensure hands, clothing (especially belts) are clear of fan blades and other moving or hot parts of engine, remove ties and contain long hair.
8 DO NOT smoke or allow a spark or flame in the vicinity of battery or engine.
1.3. General Safety Instructions
9 Familiarise yourself with the application and limitations of the charger as well as the potential hazards. Also refer to the vehicle
manufacturer’s hand book. IF IN ANY DOUBT CONSULT A QUALIFIED ELECTRICIAN.
9 Ensure the charger is in good order and condition before use. If in any doubt do not use the unit, contact your Sealey stockist.
9 Ensure the charger is disconnected from the mains supply before attaching/detaching the power clamps to/from the battery.
9 Keep tools and other items away from the engine and ensure you can see the battery and working parts of engine clearly.
9 Ensure the output of the charger is the same voltage as the battery.
9 Ensure that during charging, the charger is placed in a location where there is sufficient ventilation to prevent the build up of explosive
gases from a lead acid battery.
9 If battery has caps to access the battery fluid, remove the caps and check the fluid level before connecting the power clamps. If
necessary top-up the battery with distilled water by referring to the battery manufacturer’s instructions (Apply the personal
safety precautions described in part 1.2).
9 If the charger receives a sharp knock or blow the unit must be checked by a qualified service agent before using.
9 If the battery terminals are corroded or dirty clean them before attaching the power clamps.
9 Keep children and unauthorised persons away from the working area.
8 DO NOT dismantle the charger for any reason. The charger must only be checked by qualified service personnel.
8 DO NOT try to charge a non-rechargeable battery.
8 DO NOT try to start engine when charger is connected to battery.
8 DO NOT try to charge battery if battery fluid is frozen.
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.
8 DO NOT allow power clamps to touch each other or to make contact with any metallic part of the vehicle.
8 DO NOT cross connect power leads from charger to battery. Ensure positive (+/RED) is to positive and negative (-/BLACK) is to
negative.
8 DO NOT pull the cables or clamps from the battery terminals.
8 DO NOT use the charger outdoors, or in damp, or wet locations and DO NOT operate within the vicinity of flammable liquids or gases.
8 DO NOT use charger inside vehicle or inside engine compartment.
8 DO NOT use the charger for a task for which it is not designed.
WARNING! DO NOT simultaneously charge batteries of different capacities or discharge levels.
WARNING! If a fuse blows, ensure it is replaced with an identical fuse type and rating. Use only Sealey genuine parts.
9 When not in use, store the charger carefully in a safe, dry, childproof location.
NOTE: This appliance can be used by children aged from 8 years and above and persons with reduced physical,
sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction
concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the
appliance. Cleaning and user maintenance shall not be made by children without supervision.
2. INTRODUCTION
High frequency inverter type unit designed to both charge a battery and provide support for the battery during prolonged electronic diagnostic
checks. Charge cycle has 9 proles designed to optimise the condition of the battery and the speed of the charge. It will recover a discharged
battery (>2V) to almost 100% of its original capacity. Designed for use with lead acid and lead calcium batteries including WET, AGM/GEL
and VRLA types on 12V and 24V systems. Temperature sensor allows accurate charging of battery, even when cold. Safety circuitry prevents
sparks or polarity reversal. Once fully charged, battery may be left connected to be automatically conditioned and maintained.
3. SPECIFICATION
Model No: ...............................................BSCU25
Type: ..........................................9-Cycle with Support
Input Voltage:................................................230V
Input Current:.................................................2.4A
Charging Voltage: ......................................... 12V/24V
Charging Current 12V System: ...................................25A
Charging Current 24V System: ..................................12.5A
Battery Support Mode:........................................<300W
g.1
© Jack Sealey Limited
Original Language Version
BSCU25.V2 Issue:2 (H,F) - 27/03/18
4. OPERATION
4.1. PREPARATION
IMPORTANT! It is important to prepare for charging correctly ensuring you follow Section 1 safety regulations carefully. Check
that the capacity of the battery is compatible with the charger output.
4.1.1. Follow any vehicle manufacturer's instructions for charging the battery. Especially instructions for charging batteries which should
not ordinarily be removed from the vehicle for this process.
4.1.2. If the battery is removed, place in an appropriate safe area, according to Section 1, ready for charging.
4.1.3. A boat battery must be removed and charged on shore.
4.2. CONNECTING THE CHARGER TO A BATTERY INSTALLED ON THE VEHICLE.
4.2.1. Ensure the charger black and red crocodile clips are not short circuited at any time.
4.2.2. Identify the polarity of the battery terminals and check that they are free of corrosion deposits. Clean if required.
4.2.3. Identify the polarity of the battery terminal connected to the vehicle chassis (earth), normally the negative terminal.
4.2.4. Identify the system voltage of the vehicle, 12V or 24V.
4.2.5. Remove the battery electrolyte cover or caps, when applicable, to allow the gases produced by charging to escape.
4.2.6. If not a sealed battery, check electrolyte levels. Add distilled water in each cell according to manufacturer's instructions or 5-10 mm
above the plates if information not available. For sealed batteries refer to manufacturers recharging instructions.
4.2.7. Connect the charger POSITIVE (Red or +) lead to the POSITIVE (+) terminal of the battery and the NEGATIVE (Black or -) lead to the
NEGATIVE (-) terminal of the battery. Lay the temperature probe in close proximity to the battery (fig.1).
4.2.8. Plug the charger into the electrical supply and switch on. The LED will flash "000"; the 'standby status' in table (fig.9). Select either 12V or
24V on the selector switch, a green LED will be illuminated against the selected voltage.
4.3. CONNECTING THE CHARGER TO A BATTERY NOT INSTALLED OR TO BE REMOVED FROM THE VEHICLE.
4.3.1. Check the battery to ensure the NEGATIVE & POSITIVE terminals are clearly identifiable before removing the battery from the vehicle.
4.3.2. Disconnect and remove the battery from the vehicle and place in an appropriate safe well ventilated area ready for charging.
4.3.3. Follow instructions 4.2.6 to 4.2.8.
4.3.4. The charging status of a battery will be displayed digitally in the LED window of the charger, it can also be determined by use of a
hydrometer which measures the specific gravity of the electrolyte. The following information indicates kg/l at 20°C:
1.28 = Fully charged 1.21 = Half charged 1.14 = Fully discharged battery.
WARNING! Take care as the electrolyte is highly corrosive.
4.4. CHARGING THE BATTERY - Referring to the graphs (fig.6 and fig.7), the projected voltage is represented by the lower line and the
projected current is represented by the upper incremental line. Stages and time are represented by the numbers 1 - 9 (fig.6) for lead
acid batteries and 1 - 10 (fig.7) for lead calcium acid batteries.
4.4.1. Select the required charging mode (fig.3) by pressing the "MODE" button (fig.4). The 'vehicle' icon indicates normal charging, the
'snowflake' icon indicates low temperature environment charging, the 'Cal' indicates calcium type battery charging and is also a repair
mode for sulphated batteries. The 'battery clips' icon indicate battery support mode, this mode provides power for the battery during
prolonged electron ic diagnostic checks. If either the 'Cal' icon or the 'battery clip" icon mode is required; from the initial
flashing "000" standby mode, press the mode button in quick succession (*before the "R E P" appears in the LED window)
and follow the illuminated icon indicators to the required mode. Press three times for "Cal", four times for 'battery clips', five
times for back to standby status. For further explanation of charging modes see table fig.6. *If a charging mode selection is made;
after a few seconds "R E P" appears in the LED window, this extinguishes after 5 flashes to read the selected 'voltage/current/
charging %' from fig.4 . Selection of 'Cal' (amber) and 'battery clip icon' (red) are now inhibited and cannot be selected.
green red amber red
fig.2
Cal
4.4.2. Select the required 3 figure digital display by pressing the "display" button (fig.3) for 'voltage', press again for 'current' and again for
'charging %'. The exclamation mark indicates a fault condition. Inboard short circuit protection and overload protection instantly
shuts the charger down in a fault condition. For further explanation of displayed LED readings see table fig.5.
green green green red
display
Voltage Current Charging %
4.4.3. Check the current delivery to the battery by pressing the "display" button (fig.3). Initially, there will be a high rate of charge which will
decrease slowly according to the capacity and condition of the battery. Press again for 'current' and again for 'charging %' values.
4.4.4. When fully charged the ammeter reading 'current' should be "0.00" or close to “0.00” and the electrolyte in the battery should begin to
gas (not visible on vented sealed for life modern batteries). Press the "display" button to check the 'charging %', if the LED reads
"F U L" the battery is fully charged. If the LED reads "C H E" (stage 9 in graphs), wait whilst the charger checks the battery. If the
battery is charged fully the LED will normally change to "F U L" within 60 seconds.
4.4.5. Unless battery support mode is required, isolate mains power and unplug charger from the mains. On completion of all tasks
disconnect the power clamps, the earthed clamp first, clean the charger and store in a safe, dry area.
4.4.6. Replace the battery electrolyte cover or caps when applicable. Wipe up any splashes or spillage. Return the battery to the vehicle, if
required, secure according the manufacturer’s instructions and re-connect the power leads. Check to ensure all tools are removed before
closing the bonnet.
© Jack Sealey Limited
Original Language Version
!
fig.3
BSCU25.V2 Issue:2 (H,F) - 27/03/18
fig.4
12V
24V
MODE
Cal
Select the required voltage. A single press of the
button will change voltage illuminating a green
indicator.
To select charging mode or re-set during charging.
A single press of the button moves to next mode.
Mode : 14.4V 25.0A or 28.8V 12.5A. This mode is
normally used for all types of batteries. On
selection the charger cooling fan starts.
Mode : 14.7V 25A or 29.4V 12.5A. This setting is
recommended at temperatures below 5°C. Not
recommended when temperatures exceed 5°C.
Mode : Calcium select for all calcium batteries. Also
batteries with voltages below 10.5V without
capacity to absorb charging current. The charger
will automatically pulse charge up to 16V to recover
battery. If the battery cannot be recovered after 2
hours a fault (!) icon will illuminate. New battery
required.
Mode : DC supply (13.5V 25A) Provides support for
the battery during prolonged electronic diagnostic
checks.
fig.5
display
Voltage
Current
Charging %
!
Digital LED display to show Voltage, Current, and
Charging %. It will also display status, functions and
fault conditions. See section on Trouble Shooting.
Press display button once to illuminate Voltage, press
again to illuminate Current, press again to illuminate
Charging %. Read values in the LED window.
Read values in the LED window.
Read values in the LED window.
Read values in the LED window.
When the exclamation mark indicator illuminates, it is
accompanied by a high pitched audible alarm. A fault
condition has been detected and will be identied in
the LED window as F 0 1, F 0 2, F 0 3, F 0 4 and
F 0 5, see section 6 "TROUBLE SHOOTING".
i (A)
1 2 3 4 5 6 7 8 9 t
u(V)
© Jack Sealey Limited
Lead acid battery charge graphical representation
Original Language Version
fig.6
Charging stages
(9 steps)
1 - Qualication
2 - Battery recovery
3 - Soft start
4 - Pulse mode
5 - Recondition
6 - Bulk
7 - Absorption
8 - Equalisation
9 - Check
t
BSCU25.V2 Issue:2 (H,F) - 27/03/18
i(A)
1 2 3 4 5 6 7 8 9 10 t
u(V)
fig.7
Charging stages
(9 steps)
1 - Qualication
2 - Battery recovery
3 - Soft start
4 - Pulse mode
5 - Recondition
6 - Bulk
7 - Absorption
8 - Equalisation
9 - Check
10- Maintenance
Lead Calcium acid battery charge graphical representation
t
5. CARE AND MAINTENANCE
5.1. After each use clean the charger clamps, removing corrosive battery fluids.
5.2. Clean the charger casing and charger leads with a soft cloth and mild detergent solution.
5.3. Keep the charger leads loosely coiled during storage without snagging or crushing.
8 DO NOT attempt to repair damaged leads, these must be replaced by your Sealey service agent or a qualified person.
8 DO NOT attempt to repair charger electronics, this must be done by your Sealey service agent or a qualified person.
6. TROUBLE SHOOTING
CODES DESCRIPTION TROUBLE SHOOTING
Standby status.
Check battery status before
charging.
Charger is repairing battery
1) No connection to battery
2) Short circuit
3) Reversed polarity connection
Clip loosened during charging.
The charger stops,an audible
alarm will sound in 25secs.
Battery voltage too high.
Current leakage inside battery.
Charger internal temperature
too high.
Battery fully charged. Voltage
held until power removed.
Battery already fully
.
charged
Temporary indication of
start. Repair mode for
sulphated batteries
1) Reconnect terminal
2) Check all connections
3) Reverse connections
Check connections and
start charging process
again.
Battery voltage not as
voltage setting.
Start charging again, if
fault condition reoccurs,
replace battery.
Cooling fan not working.
Ambient temperature too
high. (40°C)
.
fig.8
ENVIRONMENT 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 any fluids (if applicable) into approved containers and dispose of the product and 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.
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 is required for any claim.
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 sales@sealey.co.uk www.sealey.co.uk
© Jack Sealey Limited
Original Language Version
BSCU25.V2 Issue:2 (H,F) - 27/03/18
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