SEALEY START800 Starter Charger Instructions

: June 12, 2024
: SEALEY

Table of Contents

SEALEY START800 Starter Charger
Product Information
Product Usage Instructions
SAFETY
INTRODUCTION
SPECIFICATION
OPERATION
ENVIRONMENT PROTECTION
Warranty
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SEALEY START800 Starter Charger

SEALEY-START800-Starter-Charger-product

Product Information

Product Name: STARTER/CHARGER 800/110AMP 12/24V 400V
Model Number: START800
Manufacturer: Sealey

Description:
This starter/charger is designed to provide a high-standard, trouble-free performance when used correctly and maintained properly. It can be used for charging batteries with a capacity of 800/110AMP and supports both 12V and 24V systems. The product operates on a 400V power supply.

Product Usage Instructions

Safety Precautions:

Wear eye protection when using the product.
Wear protective gloves when handling corrosive substances.
Protect the product from rain and use it in well-ventilated areas.
Keep the product away from sources of ignition to prevent battery explosion.
Ensure hands, clothing, and hair are clear of fan blades and other moving or hot parts of the engine.
Avoid smoking or allowing sparks or flames near the battery or engine.

Charging Safety Instructions:

Familiarize yourself with the application, limitations, and potential hazards of the charger. Consult the vehicle manufacturer’s handbook if needed.
Ensure the charger is in good condition before use. If in doubt, do not use it and contact your Sealey stockist.
Use the starter/charger in an upright position on a stable surface that can support its weight.
Disconnect the charger from the mains supply before attaching or detaching the power clamps to/from the battery.
Keep tools and other items away from the engine and ensure clear visibility of the battery and working parts of the engine.
Ensure the charger output voltage matches the battery voltage.
Place the charger in a well-ventilated location during charging to prevent the build-up of explosive gases from a lead-acid battery. Do not cover or obstruct the charger ventilation louvers.
If the battery has caps to access the battery fluid, remove them and check the fluid level before connecting the power clamps.
If necessary, top-up the battery with distilled water following the battery manufacturer’s instructions and apply personal safety precautions.
If the charger receives a sharp knock or blow, have it checked by a qualified service agent before using it.
Clean corroded or dirty battery terminals before attaching the power clamps.
Keep children and unauthorized persons away from the working area.
Do not disassemble the charger. It should only be checked by qualified service personnel.
Do not attempt to charge a non-rechargeable battery or a battery with frozen fluid.
Warning: To prevent sparking, short circuit, and possible explosion, do not drop metal tools in the battery area or allow them to come in contact with the terminals.

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.

$SEALEY-START800-Starter-Charger-fig- $1$$

SAFETY

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 minimized by the installation of appropriate safety devices. A Residual Current Circuit Breaker (RCCB) should be incorporated into 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 that is not protected by an RCCB. If in any doubt consult a qualified electrician. You must also read and understand the following instructions concerning electrical safety.

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.
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.

Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.1.1. and 1.1.2. and use a Portable Appliance Tester.
Ensure that cables are always protected against short circuits and overload.
Regularly inspect power supply leads, plugs for wear and damage, and power connections, to ensure that none is loose or damaged.

WARNING!
ELECTRICAL INSTALLATION OF START800 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:
This product must be fitted with a 3-phase plug according to the diagram to the right and will require a 32A 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.
DO NOT use this product with a standard extension cable. Only use an ARMOURED extension cable. cable.

GENERAL SAFETY

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.
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 specific 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.

PERSONAL PRECAUTIONS

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.
Wear safety eye protection and protective clothing. Avoid touching eyes while working near the 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 that is high enough to weld a ring or the like to metal, which would cause severe burns.
Ensure 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 the battery or engine.

CHARGING SAFETY INSTRUCTIONS

Familiarise yourself with the application and limitations of the charger as well as the potential hazards. Also, refer to the vehicle manufacturer’s handbook. IF IN ANY DOUBT CONSULT A QUALIFIED ELECTRICIAN.
Ensure the charger is in good order and condition before use. If in any doubt do not use the unit, contact your Sealey stockist.
Use the starter/charger in the upright position only and ensure it is placed on a stable surface that will adequately support its weight.
Ensure the charger is disconnected from the mains supply 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 working parts of the engine clearly.
Ensure the output of the charger is the same voltage as the battery.
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 louvers.
If the 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 1.3).
If the charger receives a sharp knock or blow the unit must be checked by a qualified service agent before use.
If the battery terminals are corroded or dirty clean them before attaching the power clamps.
Keep children and unauthorized persons away from the working area.
DO NOT disassemble the charger for any reason. The charger must only be checked by qualified service personnel.
DO NOT try to charge a non-rechargeable battery.
DO NOT try to charge the battery if the 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.
DO NOT allow power clamps to touch each other or to make contact with any metallic part of the vehicle.
DO NOT cross-connect power leads from charger to battery. Ensure positive (+/RED) is to positive and negative (-/BLACK) is to negative.
DO NOT pull the cables or clamps from the battery terminals.
DO NOT use the charger outdoors, or in damp, or wet locations, and DO NOT operate within the vicinity of flammable liquids or gases.
DO NOT use a charger inside the vehicle or inside the engine compartment.
Ensure there is effective ventilation to prevent a build-up of explosive gases and do not cover or obstruct charger ventilation louvers.
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’s genuine parts.
When not in use, store the charger carefully in a safe, dry, childproof location.

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 done by children without supervision.

INTRODUCTION

Heavy duty starter/chargers for professional garages, workshops or body shops. The START range caters for all requirements from cars right up to light commercial vehicles. START 800 features a fast-charge timer device to enable rapid battery recovery with reduced risk of boiling the battery. All models have large wheels for easy mobility and feature analog ammeters and switchable charge circuitry for accurate charge control.

SPECIFICATION

Model no: ……………………………………………………..START800
Output: ………………………………………………………………12/24V
Output charge peak(EN): …………………………………..110(75A)
Output start peak(EN): ………………………………….800A(640A)
Battery range: ……………………………………………….20-1200Ah
Input charge: …………………………………………………………….4A
Input start:………………………………………………………………28A
Charging rates: …………………………………………………………..8
Supply:………………………………………..400V 3ph – 32A Supply
Polarity protection: ………………………………….Fuse (3 x 110A)
Consumable parts:
START360.F10 (Pack of 10) – Fuse, START360.F (Single) – Fuse

Note: Performance is dependent on connection to an adequate good clean electric supply.

OPERATION

Refer to Fig. 1

ASSEMBLY
Slide the axle through the casing at the bottom rear corner. Slide a wheel onto each end of the axle and retain them with the circlips provided.

PREPARATION

It is important to correctly prepare for charging ensuring that you follow Section 1 safety requirements carefully.
Check that the capacity of the battery is compatible with charger output.
Follow any vehicle manufacturer’s instructions regarding battery charging. Note special instructions for the charging of non-removable vehicle batteries.
Check the battery to ensure that the POSITIVE and NEGATIVE terminals are clearly identifiable before removing the battery from the vehicle.
Disconnect and remove the battery from the vehicle and place in an appropriate safe area ready for charging.
Remove the battery electrolyte cover or caps to allow the gases produced by charging to escape.
Check that 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.
The correct charging status of the battery may be determined by using a hydrometer which will measure the specific density of the electrolyte. The following figures (kg/ltr) apply at 20°C:
- 1.28 = Fully charged, 1.21 = Half charged, 1.14 = Fully discharged.
WARNING! Be cautious and vigilant as the electrolyte is highly corrosive sulphuric acid.

CONNECTING CHARGER TO BATTERY

For chargers with dual voltage output, set the charger voltage to match that of the battery (i.e. 12 or 24 volts) by connecting the positive (red) clamp lead to either the 12 volt + output terminal or the 24 volt + output terminal as appropriate.
Check the charger clamps and battery terminals to ensure that they are clean and free from oxidation.
First connect the charger POSITIVE (Red or +) lead to the POSITIVE (+) terminal of the battery and then the NEGA TIVE (Black or -) lead to the NEGATIVE (-) terminal of the battery.

CHARGING THE BATTERY
Select charge level 1,2,3,4 using the top left hand level switch.

Check the current delivery to the battery by reading the ammeter, see fig.3, on the front of the battery charger. Initially, there will be a high rate of charge which will slowly decrease according to the capacity and condition of the battery.
NOTE: If the charger is connected to a fully charged battery the ammeter will show a low output, no charging is necessary.
SEALED BATTERIES
Charge a sealed battery very slowly, carefully monitoring the voltage across the battery terminals using a normal tester.
When the battery terminal voltage reaches 14.4V for 12V batteries or 28.8V for 24V batteries, stop charging.
MULTIPLE CHARGING
WARNING! DO NOT simultaneously charge different types of battery or batteries with different capacities or levels of discharge.
Simultaneous multiple charging should be carried out in series, since this enables monitoring of the current circulating in each battery. See fig.4 below.
NOTE: If two batteries with rated voltages of 12V are connected in series, move the positive cable to the 24V terminal.
When fully charged, the ammeter reading should be close to “0” and the electrolyte in the battery should begin to gas. Stop charging to protect the battery plates from damage. DO NOT continue to charge a fully charged battery, as this will damage the battery. DO NOT leave a battery on charge unattended. $SEALEY-START800-Starter-Charger-fig- $5$$

END OF CHARGING

Switch the charger off and unplug from mains power. Disconnect the power clamps, clean the charger and store in a safe, dry area.
Replace the battery electrolyte cover or caps. Wipe up any splashes or spillage (remember that the electrolyte is a corrosive a cid).
Return the battery to the vehicle, secure according the manufacturer’s instructions and re-connect. Check to ensure that all tools are removed before closing the bonnet or boot.

RAPID CHARGING

START 800 has a rapid charge function which is controlled by the fast-charge timer device to a maximum of 60 minutes.
To initiate rapid charging turn the fast-charge timer device (bottom right hand switch, fig.2) to the required charging time in minutes and turn the charging level rotary (top left switch to the 2 timer position).
Turn the on/off switch to the on position.
When the preset time has elapsed the current is automatically switched off and the bell will ring briefly.

STARTING

WARNING! DO NOT attempt to start engine with starter/charger if the battery is disconnected from the vehicle. The presence of the battery is essential for the elimination of possible over voltage that may be generated due to energy accumulating in the connection cables at the starting stage.
Check the vehicle manufacturer’s handbook and follow any special instructions. Check that the battery is in good condition.
Ensure the starter/charger is disconnected from the mains power supply and, for models with dual voltage output, set the output voltage to the same as the vehicle battery i.e. 12 or 24 volts.
Check that the charger clamps and battery terminals are clean and free from oxidation.
Without removing the cables that connect the battery to the vehicle, first connect the charger POSITIVE (red) lead to the POSITIVE (+) terminal on the battery. Then connect the NEGATIVE (-) (black) lead to the chassis, remote from the battery and the fuel line. Starting will be greatly eased if the battery is given a short charge before the ignition switch is turned. Plug starter/charger into mains power supply, select a low rate of charge and turn on. Allow the battery to charge for 2-3 minutes.
Move the top left hand switch to the ‘START’ position (see fig.2). Turn the vehicle ignition on and crank the engine for a MAXIMUM of 3 seconds. If the vehicle does not start, wait 120 seconds and then try again to a maximum of 5 cycles.
WARNING! If the vehicle will not start, DO NOT continue as vehicle battery and electrical circuits may be damaged, and the fuse in the charger will blow. Disconnect the charger and investigate for vehicle faults.
When the vehicle is running successfully, switch the starter/charger off, unplug from the mains power and disconnect the power terminals from the battery.

FUSE see fig.2

The starter/charger is equipped with a safety fuse, or fuses, which will cut the power to the unit in the following circumstances:

Overload – too high a current to the battery
Short circuit – clamps touch, or cross-connection to battery
Prolonged starting attempts $SEALEY-START800-Starter-Charger-fig- $4$$

Should the fuse blow take the following action:
Turn the unit off and disconnect from the mains power supply. Allow the unit to cool down, establish the reason for failure and correct. Replace the fuse (under fuse cover on control panel). DO NOT use a fuse with copper bridge or similar as these will damage your starter charger. Refer to Section 2 ‘Specifications’ for fuse information. We recommend that you hold at least 3 spare fuses with the starter/charger.

NOTE:
The use of an incorrect fuse will invalidate your warranty.

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.