Sealey SUPERSTART1020.V3 Instructions Manual

INSTRUCTIONS FOR:

STARTER/CHARGER

MODEL No: SUPERSTART1020.V3

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.

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.

1. SAFETY INSTRUCTIONS

IMPORTANT: THE SUPERSTART1020.V2 MUST BE CONNECTED TO A 3 PHASE 415 VOLT SUPPLY. (SEE SECTION 1.2)

THE FOLLOWING STATEMENTS ON ELECTRICAL SAFETY MUST ALSO BE READ AND UNDERSTOOD BEFORE USING THE
STARTER/CHARGER.

1.1. 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.

1.1.1. 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.

1.1.2. 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.

1.1.3. 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).

1.1.4. DO ensure that cables are always protected against short circuit and overload.

1.1.5. DO regularly inspect power supply, leads, plugs for wear and damage and all electrical connections to ensure that none is loose.

1.1.6. 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.

1.1.7. 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.

1.1.8. DO NOT use worn or damage leads, plugs or connections. Immediately replace or repair by qualified persons.

1.1.9. WE DO NOT RECOMMEND THE USE OF AN EXTENSION CABLE WITH THE CHARGER AS THE POWER OUTPUT MAY BE SERIOUSLY REDUCED.

 1.2 WARNING! ELECTRICAL INSTALLATION OF THE SUPERSTART1020 TO A 3 PHASE 415VOLT SUPPLY

MUST ONLY BE CARRIED OUT BY A QUALIFIED ELECTRICIAN. Make sure the power supply cable is correctly

connected to the Earth. It is the user’s responsibility to read, understand and comply with 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.

1.2.1 This product must be fitted with a 3 phase plug according to the diagram to the right, and
will require a minimum of 16AMPs per phase, (preferably 32AMP) electrical supply. You
must contact a qualified Electrician to ensure an appropriately fused supply is available.

Connect GREEN/YELLOW wire to Earth ‘E’
Connect GREY wire to L1 Terminal.
Connect BROWN wire to L2 Terminal.
Connect the BLACK wire to terminal L3.
When completed, check there are no bare wires, that all wires have been connected
correctly and the cable restraint is tight.

1.2.2 DO NOT use this product with a standard extension cable. Only use ARMOURED extension
cable.

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.

1.3. PERSONAL PRECAUTIONS

 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.

 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 or the like to metal, which may cause severe burns.

 Ensure hands, clothing (especially belts) are clear of fan blades and other moving or hot parts of engine, remove ties and contain long hair.
 DO NOT smoke or allow a spark or flame in the vicinity of battery or engine.

Original Language Version

SUPERSTART1020.V3 Issue: 3 - 22/10/10

1.4. GENERAL SAFETY INSTRUCTIONS

 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.

 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.
 Only use recommended attachments and parts. To use non-recommended items may be dangerous and will invalidate your warranty.
 Use the starter/charger in the vertical position only and ensure it is placed on a stable surface which will adequately support the weight.
 Ensure the starter/charger is ‘Off’ before attaching/detaching the power clamps to/from the battery.
 Keep tools and other items away from the engine and ensure you can see the battery and moving parts of the engine clearly.
 Ensure the voltage on the starter/charger is set to the same voltage as the battery. Check position of positive battery cable.
 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 para. 1.3).

 The cables may become hot with excessive use. If so, allow a few minutes for them to cool down before attempting to re-use.
 If the starter/charger receives a sharp knock or blow the unit must be checked by a qualified service agent before using.
 If the battery terminals are corroded or dirty clean them before attaching the power clamps.
 Keep children and unauthorised persons away from the work area.
 DO NOT dis-assemble the starter/charger for any reason. The starter/charger must only be checked by qualified service personnel.
 DO NOT try to charge a non-rechargeable battery.
 DO NOT try to start engine, or to charge battery, if battery 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.

 DO NOT allow power clamps to touch each other or to make contact with any metallic parts of the vehicle.
 DO NOT cross connect power leads from starter/charger to battery. Ensure positive (+) (RED) is to positive and negative (-) BLACK is to

negative.
If symbols cannot be distinguished, remember that the negative terminal is the one directly connected to the vehicle bodywork.

 DO NOT pull the cables or clamps from the battery terminals and DO NOT remove power clamps while the starter/charger is ‘On’.
 DO NOT use the starter/charger outdoors, or in damp or wet locations and DO NOT operate within the vicinity of flammable liquids or gases.
 DO NOT use starter/charger inside vehicle or inside engine compartment. Ensure there is sufficient ventilation and do not cover or obstruct

starter/charger ventilation louvres.

 DO NOT use this product to perform a task for which it is not designed.
 WARNING! Simultaneous charging of batteries is possible but must be done with great caution by a qualified person. Contact your

Sealey dealer for information and accessories. DO NOT charge in series two batteries of differing type, capacity, or levels of discharge.

 WARNING! If a fuse blows, ensure it is replaced with an identical fuse type and rating.
 When not in use, store the starter/charger carefully in a safe, dry, childproof location. ,

2. SPECIFICATIONS

MODEL NO: ...............................................SUPERSTART1020.V3

Volts Input.........................................................................415V 3ph

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

Output 12V Charge Peak (EN) ............................. 120A(80A)(90A)

Output 24V Charge Peak (EN) ............................. 120A(80A)(90A)

Output 12V Start Peak (EN) .......................................1000A(640A)

3. ASSEMBLY

Output 24V Start Peak ;(EN) ......................................1000A(640A)

Input Charge.......................................................................... 4A/8A

Input Start ..................................................................................30A

Fuse Ref (quantity) ..................................................120/122452 (3)

Pack of 10 fuses........................................................... 120/802131

3.1. ASSEMBLY. Assemble handle to top of casing using four bolts
provided as indicated in fig.2.

3.1.1. Insert axle through bottom back corner of casing. Slide a wheel onto
either end of axle and retain with washers and fixings provided.

3.1.2. Attach the black clamp to the fixed cable that comes directly out of
the charger. (See fig.3)

3.1.2. Attach the red clamp to the moveable cable. (See fig.3)

fig.1 fig.2

4. OPERATING INSTRUCTIONS

 WARNING! Ensure you have read and understood all safety instructions before using the charger.

4.1. PREPARATION It is important to correctly prepare for charging - follow Section 1 safety requirements and, especially when
charging battery in situ, any vehicle manufacturer's instructions. Check that capacity of battery is compatible with charger output.

4.1.1. Check battery to ensure the NEGATIVE & POSITIVE terminals are clearly identifiable before removing the battery from the vehicle.

4.1.2. Disconnect and remove the battery from the vehicle and place in an appropriate safe area ready for charging.

4.1.3. Remove the battery electrolyte cover or caps to allow the gases produced by charging to escape.

4.1.4. 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.

4.1.5. The correct charging status of the battery may be determined by use of a hydrometer which measures the specific density of the
electrolyte The following information indicates kg/l at 20oC:

1.28 = Fully charged 1.21 = Half charged 1.14 = Fully discharged battery.

 WARNING! Be cautious and vigilant as the electrolyte is highly corrosive sulphuric acid.

Original Language Version

SUPERSTART1020.V3 Issue: 3 - 22/10/10