SEALEY ECS350 Electronic Starter Charger Maintainer User Manual

350/60A 12/24V ELECTRONIC STARTER/
CHARGER/MAINTAINER
MODEL NO: ECS350

ECS350 Electronic Starter Charger Maintainer

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.

SAFETY

1.1.   ELECTRICAL SAFETY

 ‰ WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following: ou must check all electrical products, before use, to ensure that they are s afe. 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.

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 circuit and overload.

Regularly inspect power supply leads and plugs for wear and damage and power connections to ensure that none is loose or damaged.

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.

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

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

DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty item repaired or replaced by a qualified electrician.

This product requires an electrical supply in excess of 13 amp, 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.

IT IS RECOMMENDED THAT THE SUPPLY TO THIS PRODUCT IS FITTED WITH A 16AMP FUSE OR BREAKER

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.

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.

WARNING! Modern vehicles contain extensive electronic systems. You are required to check with the vehicle Manufacturer, for any this product is not used in accordance with all instructions.

INTRODUCTION

Fully electronic, microprocessor controlled battery starter/charger designed to meet the requirements of modern battery technology.
Suitable for EFB & AGM/GEL (stop/start), Lead Acid, Lead Calcium & Silver Calcium batteries found on electric and hybrid vehicles.
Features up to ten analysis and charge phases, including trickle/maintenance and suitable for 12V and 24V electrical systems. Instant visual check of battery condition, charge current, voltage and charging rate via LED read-out. Stabilised charging current  allows improved charging efficiency and reduced charging times using ECS (Electronic Control Systems) technology. Includes circuitry to provide surge and spike protection during charging and starting, preventing damage to vital systems such as ABS, airbag  sensors, ignition and music systems. Features power supply mode, providing support for the battery to prevent it from being drained during prolonged electronic diagnostic checks and software updates.

SPECIFICATION

Output Voltage: ……………………………………………12/24V
Output Charge Peak (EN) …………………………. 60A(40A)
Output Start Peak (EN) …………………………. 350A(250A)
Battery Range ……………………………………………4-450Ah
Input Charge ………………………………………….. 1.1KW-5A
Input Start ………………………………………………. 6KW-26A
Charging Rates … 3xPreset+1XVariable to Max. Current
Supply …………………………………………………….230V 16A
BSU …………………………………………………….. 25A-13.5V
Polarity Protection ……………………………….Fuse (2x80A)
Fuse …………………………………………………… 120/122351

ASSEMBLY

1. Carefully unpack all components and prepare a surface on which you can lay the unit down on during assembly, without damaging it.
2. Insert the handle (fig.1.1) and secure it through the rear of the unit with screws (fig.1.2).
3. Screw on the clamp holders to each side (fig.1.3).
4. Use the long screws to screw on the cable retainers and spacers on each side (fig.1.4).
5. Lay the unit on its front in order to insert the axle. Fit the wheels (fig.1.5), then their retainers and caps (fig.1.6).
6. Clamp Assembly (fig.2).
7. Push cable through insulating handles.
8. Locate cable using cable screw washer and nut, note which way up cable needs to be. Screw on cable clamp tightly.
9. Screw up cable screw tightly.
10. Push outer protection pieces onto the ends of the clamp.
11. Slide insulating handles up to meet the outer protection pieces.
12. Repeat for all four clamps.

CONTROL PANEL

5.1. SIGNALLING LEDS
There are 15 LEDs on the front panel having the following functions:

• 4 battery status LEDs, indicating:
  Full: battery is charged and is in Charge Maintenance status.
  Charging: battery charging.
  Fault: battery is damaged.
  Reverse: polarity reversal.

• 1 battery charger status LED: ON LED, battery charger ON (colour BLUE).

• 1 operating status LED: indicates whether output is in accordance with selected mode.
  Correlated with the Start/Stop button (Colour YELLOW).

• 3 LEDs on Function operating mode: Charge, Start or Supply (colour YELLOW)

• 4 battery capacity indication LEDs: Set Capacity described in section 6.2. (colour YELLOW).

• 2 battery type indication LEDs: Battery Type described in section 6.3. (colour YELLOW).

5.2. OPERATING MODE SELECTION BUTTONS
There are 5 buttons on the front panel which have the following functions:

• Start / Stop: starts or stops supply in the selected mode.
• Function: selects operating mode.
• Set Capacity: selects battery capacity.
• Battery Type: selects the type of battery to charge.
• A/V: selects the information to be displayed.

5.3. AL DISPLAY DIGIT
5.3.1. A/V button:The A/V selector button selects voltage or current display or allows the user to change the display language.
Pressing the A/V button toggles from voltage display U to current display A, and finally the Language menu. This menu will show the message “LANGUAGE = ITALIAN” or another language, depending on the selection.

5.3.2. Change Display Language.
To enter the language selection mode, press the A/V button and hold it down when the display is showing the message
“LANGUAGE = ITALIAN”. The language setting is Italian by default; to scroll the language menu press the A/V button again and the language shown will change instantly. Languages supported: • Italian • English.
Once the language is set, to quit the menu press the A/V button for a few seconds.

OPERATING MODES

6.1. FUNCTION
Note: All modes support both 12V and 24V batteries (voltages stated for 12V batteries).
6.1.1. CHARGE MODE
Battery charging mode. Provides 11 charging steps as described below:

• STEP 1: Analysis 1: If the battery output is less than 10.5V the unit proceeds with the next analysis. Outputs below 5V will cause the charger to revert to stand-by.
• STEP 2: Analysis 2 (sulphated battery): The display shows the message “ANALYSIS” alternating with the instantaneous voltage or current. After this step the unit either starts the charging cycle directly or it displays the message  “SULPHATED BATTERY” to inform the operator that the battery must be recovered.
• STEP 3: Desulphation: Pulsed voltage to prevent sulphation of the battery.
• STEP 4: Controlled current: Charges the battery up to the programmed limit value.
• STEP 5: Analysis 3 (elements short circuited): Checks whether the battery has short circuited elements or is damaged and reports the error, if present.
• STEP 6: Deep Cycle Charging: Central charging cycle.
• STEP 7: Constant Voltage: Keeps the battery at the charging end voltage.
• STEP 8: Analysis 4:. Checks whether the battery has short circuited elements or is damaged and reports the error, if present.
• STEP 9: Trickle charging: Maintains the battery at 13.8V (WET) or 13.5V (AGM/SPIRAL CELL).
• STEP 10: Analysis 5: Checks whether the battery has short circuited elements or is damaged and reports the error, if present.
• STEP 11: Pulsed current cycle: Cycle that simulates the normal life cycle of the battery.

START MODE

To start a vehicle with a flat battery, this mode consists of the following steps:

• STEP 1:Battery analysis: The charger’s Start LED flashes.
• STEP 2:Fast Charging: The charger enters this step if the Start LED is steadily on. It sets the charge end voltage associated with the selected battery type with the current limit defined for the Start step.
• STEP 3:Engine Boost: When the battery charger detects an engine cranking attempt, it switches to the next step. If the battery voltage reading is above 13.5V the scrolling message START appears on the display.
• STEP 4:Boost: The scrolling message START appears on the display: the battery charger is now delivering the maximum power. Supply Mode.

Power supply mode to assist in vehicle programming. This mode does not contain any charging steps, and it consists exclusively of a stabilised power supply delivering the nominal battery voltage. The purpose is that of supplying current to support the battery to prevent it from being drained during operations that require power for short or long periods.

RECOVERY MODE

WARNING: because of the high voltage reached during this cycle, the battery recovery process MUST be performed with the battery disconnected and removed from the vehicle. Recovery with the battery connected to the vehicle may result in damage to the vehicle’s electronics.
This is the method of recovery for sulphated batteries accessible by means of a prolonged press of 3 seconds of the Function button. The screen displays the message RECOVERY alternating with the instantaneous voltage or current reading; during this step the Charge LED flashes.
The charger performs a special charging cycle in which higher than average voltages are forced to attempt recovery of the battery. In this mode no error messages are generated during the charging cycle.
At the end of the cycle a message is displayed to indicate whether or not the battery has been recovered on the basis of the current absorption.
This mode has six steps as described below:

• STEP 1: Analysis 1: Outputs below 1.5V will cause the device to revert to standby.
• STEP 2: Desulphation: Pulsed voltage in order to prevent sulphation of the battery.
• STEP 3: Controlled Current: Charges the battery up to the programmed limit value.
• STEP 4: Deep Cycle Charging: Central Charging Cycle.
• STEP 5: High Voltage: Keeps the battery at high voltage for 2 hours to attempt to break down the sulphate crystals that have formed in the battery.
• STEP 6: Analysis 2: Checks whether or not the battery has been recovered.

CHARGING MODE

Set Capacity.

Preset charging bands to select the connected battery, or for expert users, manual setting of the output current as a percentage of the maximum current supported by the operating mode currently selected on the battery charger Manual Current Setting.

Specifically:

• Charge: settable charging band.
• Start: settable charging band.
• Supply: Settable supply band, by Manual Current Setting.

Charge 4Ah – 450Ah (Manual).
Supports all batteries from a minimum of 4Ah up to a maximum of 450Ah.
Output current is adjustable from 0 up to the maximum supported by the operating mode currently selected on the battery charger. Charge 120Ah – 200Ah.
Supports batteries from 120Ah up to 200Ah. Output current adjusted automatically.
Charge 80Ah – 120Ah.
Supports batteries from 80Ah up to 120Ah. Output current adjusted automatically.
Charge 30Ah – 70Ah.
Supports batteries from 30Ah – 70Ah. Output current adjusted automatically.

BATTERY TYPE

Wet:Acid electrolyte batteries.
Agm-Spiral Cell:AGM batteries with flat plate or Optima type spiral cell.
SAVING SETTINGS
The battery charger saves the settings made on the control panel. In the event of an accidental power loss or voluntary power off, when the charger is restarted, it will restart with the latest saved settings, including the Start/Stop status.

BATTERY ANALYSIS
The analysis stages within the operating modes may terminate with the signalling of various errors:

• Damaged Battery: the Fault LED switches on and the Start/Stop LED switches off and the charger enters Standby mode. The display shows the message Errxx where xx is the number corresponding to the cause of the error (see table 1). Single 10 second audible warning.
• Polarity reversal: the Reverse LED switches on and the display shows the message Err07 with a two second audible warning.
• Analysis step in: Charge: the display shows the scrolling message ANALYSIS alternating with the measured voltage or current value; the LED corresponding to the function continues to flash until the analysis is concluded. If the battery is in good condition, the LED will be on, otherwise the display shows scrolling message SULPHATED BATTERY and an intermittent audible warning is emitted.
• Analysis step in: Start: in the preliminary analysis function in Start, the LED of this mode will flash until a current absorption exceeding a minimum threshold is detected, after which the LED remains on and the vehicle engine can be started.

6.6. ERROR CODES

correctly and start charging the battery again; (see section: 7.2. Operating the Charger).
| Battery completely short-circuited.| The battery could be defective. Contact your nearest battery service centre.
Err02| Battery faulty or unrecoverable
No current accepted after 10 hours of recovery.| The battery could be defective. Contact your nearest battery service centre.
Err03| Internal overheating of battery charger Battery charger overload.| Remove any objects that could be covering the ventilation area of the battery charger or move it to a cooler area. Wait for the battery charger to start again automatically.
Err04| Tension Error.| Set again the voltage corresponding to that of the battery. Start charging the battery again (see section: 7.2. Operating the Charger).
| One or more elements of the battery has/have short-circuited.| The battery could be defective. Contact your nearest battery service centre.
Err05| Battery voltage too high compared to that set. (You are attempting to charge a 24V battery with the battery charger set at 12 Volt).| Set again the voltage corresponding to that of the battery. Start charging the battery again (see section: 7.2. Operating the Charger).
Err06| Battery capacity excessive Unable to reach end condition.| Use a battery charger with greater capacity.
Err07
and LED REVERSE| The clamps of the output leads are not connected correctly to the battery.| Position the clamps correctly and start charging the battery again
(see section: 7.2. Operating the Charger).
Err08| Excessively high output current Current exceeds maximum limit.| Reduce output current when in manual mode.

OPERATION

7.1. CHARGING CONNECTIONS

7.1.1. Charging batteries connected to the vehicle.
7.1.2. Before starting to charge the battery, make sure the power supply lead is NOT plugged into the mains supply.
7.1.3. Locate the vehicle’s earthing point, which is normally connected to the negative battery terminal.
7.1.4. Charging a battery with negative earth, grounded to the vehicle’s chassis:

• Connect the output lead with red clamp to the positive terminal (+) of the battery.
• Connect the output lead with black clamp to the vehicle’s earthing point, keeping it away from the battery and from the fuel pipes etc.

NOTE: If connecting to an older vehicle, it may be positively earthed, in which case the clamps need to be connected in reverse.

7.1.5. Charging batteries that are not connected to a vehicle.

7.1.6. Before starting to charge the battery, make sure the power supply lead is NOT plugged into the mains supply.

7.1.7. Connect the output lead with red clamp to the positive terminal (+) of the battery.

7.1.8. Connect the output lead with black clamp to the negative terminal (-) of the battery.

ATTENTION: Make sure both clamps of the output leads generate a suitable contact with their corresponding terminals.

7.2. OPERATING THE BATTERY CHARGER

7.2.1. Once the output leads are connected to the battery, check that the positive lead is connected correctly to either the 12V or 24V connector on the charger as required. Then plug the power supply lead of the battery charger into the  mains supply, making sure that the voltage matches the nominal voltage of the battery charger (230V-50Hz); having done this, the charger will emit an acoustic signal or ½ second and all the LED indicators on the control panel will  switch on for 2 seconds, the digital display shows —-.
7.2.2. ThebatterychargerisconfiguredinStandbymode,forexample:ONLEDlit,Chargelit,WetLEDlit.TheLEDslightupdifferently based on the last program saved (see section 6.4. Saving Settings).

7.2.3.       At this stage, with the battery charger in Standby mode, set the charging parameters suitable for the type of battery to be charged, using the buttons on the control panel. The charging parameters selected are displayed by the  corresponding LED, which switches on.

7.2.4.   Settable charging parameters:

• Function key: Charge, Start, Supply, Recovery.

• Set Capacity key: Based on the capacity of the battery and on the work cycle, select:
  – Charge 30Ah/70Ah: Charge for batteries with capacity from 30Ah to 70Ah.
  – Charge 80Ah/120Ah: Charge for batteries with capacity from 80Ah to120Ah.
  – Charge 120Ah/200Ah: Charge for batteries with capacity from 120Ah to 200Ah.
  – Charge 4Ah/450Ah: Supports all batteries from a minimum capacity of 4Ah up to a maximum of 450Ah.

• Type key: Depending on the construction/type of the battery, select: Wet or Agm/Spiral Cell.

7.2.5. Once the charging parameters haver been set, press the START/STOP key to start charging the battery. When the START/STOP and  CHARGING LEDs light up, the battery is being charged; the display will show the charging  current and the voltage of the battery.

7.2.6. The CHARGING LED remains lit in phases “I” and “U0” whilst the battery is charging.

MAINTENANCE

8.1. When the battery charger is not being used, it must be stored in a dry place to protect it against humidity. Use a soft cloth to clean its outer casing.

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.

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.

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.

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500
01284 703534
[email protected]
www.sealey.co.uk
© Jack Sealey Limited
Original Language Version
ECS350 Issue 3 (H) 31/08/22

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