Sealey SUPERSTART300.V5,SUPERSTART400.V2,SUPERSTART500. Instructions Manual

INSTRUCTIONS FOR

STARTER/CHARGER 300AMP,400AMP,500AMP
12/24V

MODEL NO: SUPERSTART300.V5/SUPERSTART

400.V2/SUPERSTART500.

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

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. You may obtain an RCD by contacting your local Sealey dealer.
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.

1.0.1. Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply.

1.0.2. Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure
that they are secure.Important: Ensure that the voltage rating on the appliance suits the power supply to be

 usedandthecorrecttypeofplugtted.

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qualiedelectrician.

1.0.3. If the cable or plug is damaged during use, switch the off electricity supply and remove from use.

1.0.4. This product requires an electrical supply in excess of 13 amps, and NO plug is fitted.

You must therefore contact a qualified electrician to ensure that a 16 amp supply is available.
We recommend that you discuss the installation of a industrial round pin plug and socket with your electrician.
Ensure that the unit is correctly earthed via a three-pin plug, as shown.
a) Connect the green/yellow earth wire to the earth terminal
b) Connect the brown live wire to live terminal ‘L’.
c) Connect the blue neutral wire to the neutral terminal, ‘N’ or unmarked.
d) 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.

 Sealeyrecommendthatrepairsarecarriedoutbyaqualiedelectrician.
 “Modernvehiclescontainextensiveelectronicsystems.YouarerequiredtocheckwiththevehicleManufacturer,foranyspecic

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.”

▲ 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.

1.0.5.

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.

 WARNING! Modern vehicles contain extensive electronic systems.

 YouarerequiredtocheckwiththevehicleManufacturer,foranyspecicinstructionsregardingtheuseofthistypeofequipmenton 

each vehicle.

1.0.6. No liability will be accepted for damage / injury, where this product is not used in accordance with all instructions.

1.1. 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.

Original Language Version

© Jack Sealey Limited

Wear

Protective

Gloves

Warning:

Electricity

Protect

From

Rain

Use in

Well

Ventilated

Areas

Keep away

from sources

of ignition:

Battery could

explode

Refer to

Instruction

Manual

Warning:

Explosive

Material

Wear eye

Protection

Warning:

Corrosive

substance

It is recommended

that the supply to this

productisttedwitha

16AMP Fuse or Breaker

SUPERSTART300.V5,400.V2,500. | Issue (1) 05/07/16

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.

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.

1.2.

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 Dealer.
9 Use the charger in the upright position only and ensure it is placed on a stable surface which will adequately support its weight.
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, and DO NOT cover or obstruct the charger ventilation louvres.

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 dis-assemble 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 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.

9 Ensure there is effective ventilation to prevent a build-up of explosive gases, and do not cover or obstruct charger ventilation louvres.
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.

2. INTRODUCTION

Heavy-duty professional starter/chargers for the medium and large garage, workshop and body shop operation. The SuperStart range caters for all
requirements from cars right up to passenger service and commercial vehicles.

Model No: ......................SUPERSTART300.V5......................SUPERSTART400.V2......................SUPERSTART500

Output: .........................12-24V..............................................12/24V...............................................12/24V

Output Charge Peak (EN): ..........45A(30A)..........................................60A(40A)...........................................75A(50A)

Output Start Peak(EN):.............300A(200A)......................................400A(300A).......................................500A(350A)

Battery Range: . . . . . . . . . . . . . . . . . . . 30-350Ah..........................................30-450Ah..........................................30-550Ah

Input Charge: ....................1.5KW...............................................1.5KW................................................1.5KW

Imput Start:......................5KW..................................................6KW...................................................10KW

Charging Rates: . . . . . . . . . . . . . . . . . . 4........................................................4........................................................4

Supply: . . . . . . . . . . . . . . . . . . . . . . . . . 230V..................................................230V..................................................230V

Polarity Protection: ................Fuse(1x80A)......................................Fuse(2x80A).....................................Fuse(2x80A)

3. ASSEMBLY

3.1. Assemble the handle to the main casing using the fittings provided as indicated in fig.1

3.2. Slide the axle through the casing at the bottom back corner. Attach the wheels using the fittings provided as indicated in fig.1.

3.3. The clamp with the red handle is attached to the movable cable. see fig1A

3.4. The clamp with the black handle is attached to the fixed cable which comes directly out of the top of the battery charger. see fig1A

Original Language Version

© Jack Sealey Limited

SUPERSTART300.V5,400.V2,500. | Issue (1) 05/07/16

Fig 1