Sterling power usa Pro charge ultra User manual

Pro Charge Ultra Instruction Manual

This product requires a knowledge of both AC and DC

electrical installation. Please do not install this product unless

you are qualified to do so. All effort is made to make the

instructions as safe as possible but it is not possible to cover

all electrical safety and installation aspects. Sterling can only

assume a certain basic knowledge is held by the installer.

Only to be installed by qualified personnel.

DANGER

HIGH VOLTAGE

TO AVOID SERIOUS INJURY OR DEATH FROM ELECTRICAL

SHOCK. BEFORE PERFORMING ANY ELECTRICAL WORK

ENSURE YOU TURN OFF AND REMOVE ANY AC POWER

AND CHECK VOLTAGES TO MAKE SURE THE CIRCUIT IS OFF.

DANGER

EXPLOSION HAZARD

TO AVOID SERIOUS INJURY OR DEATH MAKE CONNECTIONS

IN A WELL VENTILATED ATMOSPHERE FREE FROM

EXPLOSIVE FUMES. IT IS ADVISABLE TO WEAR SAFETY

GOGGLES WHEN WORKING NEAR BATTERIES.

DANGER

LOW VOLTAGE

TO AVOID SERIOUS INJURY OR DEATH FROM ELECTRICAL

BURNS & SPARKS ENSURE YOU DISCONNECT ANY DC

POWER AND CHECK VOLTAGES TO MAKE SURE THE CIRCUIT

IS OFF BEFORE PERFORMING ANY ELECTRICAL WORK.

CAUTION

HIGH TEMPERATURE

HOT SURFACES - TO REDUCE RISK OF BURNS DO NOT

TOUCH THE UNIT WHEN IN SERVICE.

ONLY CHARGE THE CHEMISTRY PROFILES WHICH ARE

COVERED BY THE PRESET VALUES OF THE UNIT.

IF CUSTOM SET, VALUES MUST ADHERE TO THAT OF THE

BATTERY MANUFACTURE. GETTING THE VALUES WRONG

COULD LEAD TO GASSING AND EXPLOSION OF BATTERIES.

ONLY USE THIS CHARGER WITH LITHIUM- LiFePO4 BATTERIES

IN CONJUNCTION WITH A Battery Management System FOR

FAILURE TO FIT A B.M.S. COULD RESULT IN A FIRE.

WARNING

HIGH VOLTAGE

For Multi battery type and

voltages Complementary

addition:

Battery Chemistry Module (BCM).

Allows for multiple chemistry

charging simultaneously from

one charger (different battery

types). Also allows for 24V

charging from 12V charger.

Read page 5.

PCU Top Functions:

1) 11 preprogrammed battery curves including LiFePO4.

2) 1 custom set, can be set from charger, no need for computer.

3) 2 x digital meters for current and voltage measurement.

4) 1 x power meter to show what reserve power left on the unit.

5) Active PFC, up to 0.99 pf, ensuring efficient power conversion

6) Synchronized rectification output as opposed to diode output (+10% efficiency)

7) High voltage de-sulphation cycle.

8) New, low activity, standby mode to increase battery life.

9) Battery health program.

10) Multiple speed fan control to reduce unnecessary fan noise.

11) Primary (processor digitally controlled) and an emergency backup.

12) 32 LED information panel.

13) Internal scan and systems check.

14) Remote control.

15) Small footprint and light weight.

16) Include battery temperature sensor.

17) USA CEC listed (default setting is on, CEC can be turned off). CEC

regulation stipulates that the charger is only on when necessary. This

reduces AC power consumption and lowers operational costs, while

maintaining healthy batteries.

18) % power reduction to allow unit to work with restricted input power.

19) Conforms to A.B.Y.C. drip test. Waterproof when water is dropped directly on

to the top of the unit ( +/ - 17 degrees ) if installed correctly (vertically).

20) The printed circuit boards are conformal coated for high humidity operations.

Pro Charge ULTRA

GLOBAL AC Input & Active Power Factor Correction

Sterling Power

CHARGER MODE

AC Power

Auto Temp Control

Active PFC

Multi Speed Fan

Volts Amps

AUTO CONSERVATION MODES

Fault

Absorption

Stand-by Battery Health Program

Fast Charge Float

DC Output Fault

DC Low Voltage

DC High Voltage Trip

High Charger temp trip

Check Fan

De-sulphation

1 2 3

SETUP

ENTER

CHARGE INFORMATION

Open lead acid

Sealed lead acid

A.G.M

GEL

Calcium / Custom

Lithium (LiFePO4)*

System self test Battery Type

Charger Output

0% 100%

Progressive DIGITAL software control Charger / Powerpack

High Voltage AC Low Voltage DCWARNING

www.sterling-power-usa.com

Preset 1

Preset 2

www.sterling-power.com

*Lithium must be used in conjunction

with a lithium balancing system.

Safety Certified by: TUV

Built and tested to

UL 1236 SB

CSA C22.2-107.2

RoHS

compliant

CEC

approved

To Standards:

UL 1236 SB

CSA C22.2-107.2

Tested to CE standards

EN61000-3-2 EN61000-3-3

EN55014-1 EN 55014-2

EN60335-2-29

CEC listed

RoHS

compliant

EN ISO 13297

Small Craft Directive

CEC listed

12V / 60A model, all other units pro rata.

Input voltage range 80-270V 40-70 Hz

Power Factor at 230V 0.976

Efficiency 90.4%

Full load current (110/230V) 9.8/4.6A

Total Harmonic Distortion 2.4% voltage

Total Harmonic Distortion 2.4% current

Ripple noise (R.M.S.) 14mV

Ground leakage 0.5 mA

Generator/ mains power (watts)

12V 20A approx 350W

12V 30A approx 500W

12V 40A approx 600W

12V 50A approx 750W

12V 60A approx 900W

24V 20A approx 600W

24V 30A approx 900W

36V 20A approx 900W (NOT UL / CEC LISTED)

48V 15A approx 900W (NOT UL / CEC LISTED)

voltmeter accuracy +/- 1%

Ammeter accuracy +/- 1%

GLOBAL AC Input & Active Power Factor Correction

CHARGER MODE

AC Power

Auto Temp Control

Active PFC

Multi Speed Fan

Volts Amps

AUTO CONSERVATION MODES

Fault

Absorption

Stand-by Battery Health Program

Fast Charge Float

DC Output Fault

DC Low Voltage

DC High Voltage Trip

High Charger temp trip

Check Fan

De-sulphation

1 2 3

SETUP

ENTER

CHARGE INFORMATION

Open lead acid

Sealed lead acid

A.G.M

GEL

Calcium / Custom

Lithium (LiFePO4)*

System self test Battery Type

Charger Output

0% 100%

Progressive DIGITAL software control Charger / Powerpack

High Voltage AC Low Voltage DCWARNING

www.sterling-power-usa.com

Preset 1

Preset 2

www.sterling-power.com

*Lithium must be used in conjunction

with a lithium balancing system.

Safety Certified by: TUV

Built and tested to

UL 1236 SB

CSA C22.2-107.2

RoHS

compliant

CEC

approved

Pro Charge ULTRA

Sterling Power

Warm air

out

Cooling

Air flow

Installation

1) Install in cool dry well ventilated space.

2) This product has a high heat tolerance and can be installed in an engine room.

3) This product is ignition protected and can be installed near the batteries.

4) Charger MUST be installed vertically to allow for convection air flow and also in the vertical position

5) The product is drip proof.

6) The product will work in any position but we cannot guarantee the drip proof aspect (only vertically).

Quick LED feature guide

1) Ammeter, shows the total current being

produced by the charger.

2) Voltmeter, showing the average voltage being

produced by the charger.

3) Power meter, shows the % power being produced

by the unit and the remaining power available.

4) AC power, shows the AC power is connected and

the product is live. LED flashes if power is available

but the unit is switched off (see on/off later) push

buttons. Setup and up arrow for 5 secs to activate.

5) Auto temp control, shows the battery temp sensor

is connected and operational. If sensor not

connected then the unit will default to a 20 deg C / 69

F charge curve.

6) Shows that the active PFC (Power Factor

Correction is on).

7) Fan speed control, varies depending on temp, 3

speeds.

8) Standby, charger power system power

requirement very low, unit on low float voltage to

prolong battery life.

9) Fast charge unit on constant current mode.

10) OK, unit operating within normal parameters

11) Fault, fatal fault, needs to be returned for repair.

12) Battery type selector, shows which battery

charger curve in operation (adjustable).

13) Buttons to select charge options (see later in

instructions) also used to switch unit off or on in

conjunction with the setup button (see 14).

Off select button press down button for 5 seconds.

On select button press up button for 5 seconds.

14) Button to enter selections. Also, use to switch

unit on/off in conjunction with the up or down button.

15) Battery health program, unit doing a 21 day de-

sulphation cycle.

16) , charger on initial charge cycle.Absorption

17) De-sulphation cycle operational. For safety

reasons only available when on open lead acid

battery type.

18) Float, unit on float charge or power pack mode,

main charge complete.

19) DC output service, output working correctly.

20) DC output low voltage warning, either batteries

are very low / more power is being taken than the

charger can supply / or the charger is defective.

21) High voltage trip, the unit is defective and

tripped itself, or a high back DC voltage has been

detected, like a wind generator reg gone defective.

22) High charger temp, if the unit is positioned in too

hot an environment and over heated, or the fans

have failed.

23) Check fans, if LED on, fans are defective.

24) Case screws to access the wiring of the product.

Battery type High Charge V Float Charge V Maintenance V High Charge V Float Charge V Maintenance V

Flooded/Open Lead acid 14.8 13.6 12.8 14.7 13.4 12.8

Sealed Lead acid 14.4 13.6 12.8 14.6 13.4 12.8

AGM Lead acid 14.3 13.3 13.0 14.6 13.6 13.0

GEL Lead acid 14.0 13.7 13.2 14.4 13.8 13.2

LiFePO4-Lithium 13.8 13.8 13.2 14.6 14.6 13.2

Calcium / Custom 15.1 13.6 13.2 Your choice see custom setup in instructions

Equalization / Desulph 15.5 15.5 15.5 15.5

Preset 1 Profiles Preset 2 Profilesx 2 all voltages for 24V unit x 3 for 36V x 4 for 48V

Fit this way up to

comply with UL

accordance and for

ABYC drip proofing

compliance.

Lithium Users Read.

This charger must not be used

to charge lithium battery cells

by itself. You cannot charge

lithium cells on their own. You

must have a lithium balancing

device in conjunction with this

charger.

DC installation (output from charger)

Choosing cable. unlike AC conductors, DC is very sensitive to voltage drop.

The longer the cable runs the larger the cable thickness needs to be. Ensure

only quality fire retardant cable is used.

DC - Fuse selection, as per the

diagram, each positive output from the

charger to the battery must be fused.

Choose a fuse that is about 20% higher

current rating than the maximum rating

of the charger, then round it up.

Remember, this fuse is primarily

protecting the cables and not the

product. E.g. a 20A charger would have

about a 25A fuse. A 60A charger about

a 75A fuse. A full range of fuses and

fuse holders are available from Sterling.

Ground / bonding / earthing.

This is extremely important and often

overlooked there are, in affect, 3 grounds.

1) The earth wire (AC input, the ground).

2) The chassis / bonding ground (going to

a vehicle body / boats bonding system,

the bolt on the side of the charger)

3) The DC negative.

In most installations all these will end up at

the same point. The AC power source

should be connect to the boat/vehicle

chassis (for safety). The chassis earth will

also go there and the DC negative should

also go there. In affect, bonding the total

system together ensuring any fault to the

chassis will blow a fuse. This could vary

for steel/aluminium boats.

12V/24V/36V/48V bank +

12V/24V/36V/48V bank

AC circuit breaker

Any outputs not being used should be linked

across to one that is, this is not a requirement for

these new models but is good practice as it helps

spread loads etc.

DC fuse

20% larger

amperage than

charger output

DC fuse

20% larger

amperage than

charger output

DC fuse

20% larger

amperage than

charger output

Ground / Chassis

Boat grounding

Europe DC Charge cable size ( mm2 ) for cable length

Model 1m 2m 3m 4m 5m 6m

PCU1210 2.5 mm2 4 mm2 6 mm2 10 mm2 10 mm2 16 mm2

PCU1220 4 mm2 10 mm2 16 mm2 16 mm2 25 mm2 25 mm2

PCU1230 6 mm2 6 mm2 25 mm2 35 mm2 50 mm2 50 mm2

PCU1240 10 mm2 16 mm2 25 mm2 35 mm2 50 mm2 50 mm2

PCU1250 10 mm2 25 mm2 35 mm2 50 mm2 50 mm2 n/a

PCU1260 16 mm2 25 mm2 50 mm2 50 mm2 n/a n/a

PCU2420 4 mm2 10 mm2 16 mm2 16 mm2 25 mm2 25 mm2

PCU2430 6 mm2 6 mm2 25 mm2 35 mm2 50 mm2 50 mm2

PCU3620 4 mm2 10 mm2 16 mm2 16 mm2 25 mm2 25 mm2

PCU4815 4 mm2 10 mm2 16 mm2 16 mm2 25 mm2 25 mm2

USA DC Charge cable size ( AWG ) for cable length

Model 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft

PCU1210 16 AWG 14 AWG 12 AWG 10 AWG 10 AWG 10 AWG

PCU1220 14 AWG 10 AWG 10 AWG 8 AWG 6 AWG 6 AWG

PCU1230 12 AWG 10 AWG 8 AWG 6 AWG 6 AWG 4 AWG

PCU1240 10 AWG 8 AWG 6 AWG 6 AWG 4 AWG 4 AWG

PCU1250 8 AWG 6 AWG 6 AWG 6 AWG 4 AWG 2 AWG

PCU1260 8 AWG 6 AWG 4 AWG 4 AWG 2 AWG 2 AWG

PCU2420 14 AWG 10 AWG 10 AWG 8 AWG 6 AWG 6 AWG

PCU2430 12 AWG 10 AWG 8 AWG 6 AWG 6 AWG 4 AWG

PCU3620 14 AWG 10 AWG 10 AWG 8 AWG 6 AWG 6 AWG

PCU4815 16 AWG 14 AWG 12 AWG 8 AWG 6 AWG 6 AWG

USA AC cable size ( AGM ) for cable length up to 50ft

Model 110 volt fuse/breaker 230 volt fuse/breaker

PCU1210 3 core 16 AWG 6 A 3 core 18 AWG 4 A

PCU1220 3 core 16 AWG 8 A 3 core 18 AWG 6 A

PCU1230 3 core 14 AWG 11 A 3 core 16 AWG 7 A

PCU1240 3 core 14 AWG 14 A 3 core 16 AWG 7 A

PCU1250 3 core 12 AWG 16 A 3 core 14 AWG 8 A

PCU1260 3 core 12 AWG 16 A 3 core 14 AWG 8 A

PCU2420 3 core 14 AWG 14 A 3 core 16 AWG 7 A

PCU2430 3 core 12 AWG 16 A 3 core 12 AWG 8 A

PCU3620 3 core 12 AWG 16 A 3 core 14 AWG 8 A

PCU4815 3 core 12 AWG 16 A 3 core 14 AWG 8 A

IMPORTANT

The closer to the batteries you fit the charger the better. Not only do you save

expensive cable you also get better performance from the charger. The cable

should be properly rated to 105 deg C fire resistant. Do not use solid cable or

speaker wire.

Europe AC cable size ( mm2 ) for cable length up to 15 m

Model 110 volt fuse/breaker 230 volt fuse/breaker

PCU1210 3 core 0.75 mm2 6 A 3 core 0.75 mm2 4 A

PCU1220 3 core 0.75 mm2 8 A 3 core 0.75 mm2 6 A

PCU1230 3 core 1.5 mm2 11 A 3 core 1.5 mm2 7 A

PCU1240 3 core 1.5 mm2 14 A 3 core 1.5 mm2 7 A

PCU1250 3 core 1.5 mm2 16 A 3 core 1.5 mm2 8 A

PCU1260 3 core 1.5 mm2 16 A 3 core 1.5 mm2 8 A

PCU2420 3 core 1.5 mm2 14 A 3 core 1.5 mm2 7 A

PCU2430 3 core 1.5 mm2 16 A 3 core 1.5 mm2 10 A

PCU3620 3 core 1.5 mm2 16 A 3 core 1.5 mm2 10 A

PCU4815 3 core 1.5 mm2 16 A 3 core 1.5 mm2 10 A

AC installation (input to charger)

Wiring, using ring or captive spade connections and a proper crimping tool attach the AC cables Live ( line ) Neutral and Earth / Ground. Repeat

the procedure for the breaker side of the install, support the cable every 18 inches / 0.5 m and protect from sharp edges when passing through

bulkheads and all other openings as per any standards which apply to the installation.

Pro Charge ULTRA

GLOBAL AC Input & Active Power Factor Correction

Sterling Power

CHARGER MODE

AC Power

Auto Temp Control

Active PFC

Multi Speed Fan

Volts Amps

AUTO CONSERVATION MODES

Fault

Absorption

Stand-by Battery Health Program

Fast Charge Float

DC Output Fault

DC Low Voltage

DC High Voltage Trip

High Charger temp trip

Check Fan

De-sulphation

1 2 3

SETUP

ENTER

CHARGE INFORMATION

Open lead acid

Sealed lead acid

A.G.M

GEL

Calcium / Custom

Lithium (LiFePO4)*

System self test Battery Type

Charger Output

0% 100%

Progressive DIGITAL software control Charger / Powerpack

High Voltage AC Low Voltage DCWARNING

www.sterling-power-usa.com

Preset 1

Preset 2

www.sterling-power.com

*Lithium must be used in conjunction

with a lithium balancing system.

Safety Certified by: TUV

Built and tested to

UL 1236 SB

CSA C22.2-107.2

RoHS

compliant

CEC

approved

Remove the 2 screws on the bottom

of the front cover marked number 24

on the previous pages quick guide

this will reveal the main wiring area.

High Voltage

AC cover plate

and clamp DC cable clamp

Remove the 2 screws on the AC area and the 3 screws on

the DC clamps to enable the appropriate wires to

be attached. AC input 80-270V.

Ensure secure connections and correct crimping

tools are used.

DC 12V / 24V / 36V / 48V depending on unit.

Remote control

Insert the Sterling remote control

into the remote socket (telephone type)

Please note that when the remote is inserted the

front program controls on the local panel no longer

operate, control is in the remote. Remove the

remote to use local controls.

Battery Temperature sensor

Connect the battery temp

sensor to the position

as shown, connect the

sensor end to the negative stud

terminal on one of the batteries

which you think will be in the hottest environment.

When the temp. drops the charging voltage goes up incrementally.

When the temp. increases the charging voltage goes down incrementally.

Remote control

Live Neutral Earth ( European )

Live Neutral Ground ( USA )

1 2 3 Common Negative

red red red Black (Europe) Yellow (USA)

Pos terminals on

3 x battery banks

ى5

8[93]

8[130]35

8[93]

4 [198]

2 [215]

123

8[315]

ProMariner

Pro Nautic iQ

12-60

198 mm 7 3/4 inch

85 mm

3 3/8 inch

90 mm

3 1/2 inch

260 mm

10 1/4 inch

85 mm

3 3/8 inch

215 mm

8 ½ inch

90 mm

3 ½ inch

44 mm

1 3/4 inch

dimensions

in inches

and ( mm )

12V 10-40A

24V 20A

12V 50-60A

24V 30A

36V 20A

48V 15A

Battery temperature sensor connection

AFUSES

Cut out

90 x 62 mm

PCU 12V / 30-60A &

24V 20-30A and 36V / 48V

have bolt terminals as depicted

above, rather than screw.

PCU 12V 10A & 20A models have ring

terminal screw connectors as depicted above.

N.B. the 10A model has only 2 outputs, all

other models have 3 outputs.

Earth /chassis

boats bonding

12V Sealed engine

starter Battery bank

12V LiFePO4 Lithium

Main Battery bank

24V Bow thruster

Battery bank AGM

Pro Charge ULTRA

Sterling Power

(Optional) Battery Chemistry Module

Battery Charger Chemistry Modification Module

Another great idea from Sterling. Patent Pending: GB1204145.5

What was the issue which led to the invention of this device?

A lot of new installations on modern boats require different chemistry and

even different voltage levels. For instance, you may have a 12V charger

but a 24V bow thruster or vice versa. You may also have an open lead acid

battery banks and a Lithium. This causes impossible challenges for a

standard battery charger or you may simply have one battery bank a long

way from another bank requiring very expensive cable runs to prevent

voltage drop, ( no longer a problem with the BCM ).

The solution

The new Sterling Battery Chemistry module has a unique approach to solving

this problem. We effectively place in a box a voltage booster and the output

stage from a digital charger. This means that the new device can be added to

any of the output terminals of our Pro Charge Ultra (or can be used as an add

on to most other competitor companies multiple output charger). This will

allow the main 3 (or more) output charger to be set at the lower chemistry

voltage for the likes of Gel (14.1V absorption), then, by adding the new Sterling

Multi chemistry module to one of the outputs (must be connected to an output of

a current limiting charger and cannot be connected direct to a battery. One can

adjust that output to a totally different charging chemistry profile. The output

voltage and charging curves are independent of the charger’s input voltage.

This enables a totally different chemistry to be selected. This gives all the

advantages of the multi chemistry charger without the huge extra cost, and can

be simply retrospectively fitted to any multi output battery charger (within the

limitations of the product).

Advantages of this product

1) Easy to install.

2) Fits our products and most of our competitors multiple output chargers.

or converts a single output charger into a multiple output charger.

3) 12-12V, 12-24V, 24-24V and 24-12V models.

4) 8 selectable independent latest battery chemistries to chose from and a de-

sulphation cycle, also LiFePO4 cycle .

5) Battery temperature compensation and high battery temperature trip.

6) Remote battery sense compensate for cable voltage drop.

7) 6 LEDs projecting over 20 individual charge and warning information

events.

8) Fail safe, reverts to basic charge function - about 1V less in event of a

failure. Product can be replaced / repaired at convenience.

9) High battery temperature "daisy chain" trip ( optional ). This allows every

battery to be monitored and the unit can be switched off in the event of battery

overheating - causing high battery temperature related problems.

10) Ignition fed generator to link in with sterling Pro Split R alternator splitter,

this allows the output to be further split.

11) Remote control available as an optional extra.

Which model suits my needs. Ensure that your current charger’s output is

equal to or less than the rating of the product. I.e. a 12V 60A module can be

used on any charger up to 12V 60A .

Do you want to simply add a chemistry option. I.e. a different battery type

but maintain the same base voltage i.e. 12V or 24V. In which case the

BCM1260 will allow a totally separate battery type in the 12V charger.

Do you want a different base voltage and battery type. I.e. you have 12V

charger but you want to also charge a 24V battery bank. In this case, go for the

BCM 12V-24V option this allows for the different voltage and chemistry

Long cable runs. You may have a very long cable run from the main charger

to an important auxiliary battery. Simply add one off these units at the end off

the run to boost up the voltage to the required battery type, thus reducing

cable thickness requirement and hence cost .

Battery Chemistry module

and optional remote control

(remote control not required for operation)

Example - A 12V starter battery bank (sealed lead acid).

A Lithium main battery bank and a 24V open lead acid Bow Thruster.

Main Charger

set to 14.4V

sealed lead acid

Battery Chemistry

module 1

set to LiFePO4

Battery Chemistry

module 2

set to 24V AGM

Sterling Power Products

H Charge Float

In / Unit Bat - Chem - Unit Out / Rem

Batt.

V12.2

Temp

Setup

Volts

Alarm

Select

Audible alarm on/off

hold >5 sec

Unit on/off

hold > 5 sec

Fault

Absorption

Condi

12V 12V 24V

Multi battery chemistry and voltages output options

GLOBAL AC Input & Active Power Factor Correction

CHARGER MODE

AC Power

Auto Temp Control

Active PFC

Multi Speed Fan

Volts Amps

AUTO CONSERVATION MODES

Fault

Absorption

Stand-by Battery Health Program

Fast Charge Float

DC Output Fault

DC Low Voltage

DC High Voltage Trip

High Charger temp trip

Check Fan

De-sulphation

1 2 3

SETUP

ENTER

CHARGE INFORMATION

Open lead acid

Sealed lead acid

A.G.M

GEL

Calcium / Custom

Lithium (LiFePO4)*

System self test Battery Type

Charger Output

0% 100%

Progressive DIGITAL software control Charger / Powerpack

High Voltage AC Low Voltage DCWARNING

www.sterling-power-usa.com

Preset 1

Preset 2

www.sterling-power.com

*Lithium must be used in conjunction

with a lithium balancing system.

Safety Certified by: TUV

Built and tested to

UL 1236 SB

CSA C22.2-107.2

RoHS

compliant

CEC

approved

INSTALLATION OF THE BATTERY CHARGER

- Position the charger in a cool, dry and well ventilated space, ensuring a reasonable airflow

around the charger. Do not install in a cupboard or sealed compartment.

Charger MUST be installed vertically.

Install as close to the batteries as possible, preferably within 2 meters of the batteries.

To obtain maximum waterproof / ingressproof rating (IP42) mount the charger vertically.

However, the unit will work just as well in any fastening orientation so long as it is dry.

With regards charging cooling, the unit has thermostatically controlled force draft cooling

and is thus able to remain cool whether fastened in any orientation.

Always isolate the AC power before working on it

- - Before switching on the charger it is important to set up the battery type. Please choose a

battery type from the table (at the bottom of page 2). There are so many different profiles,

and battery companies change them all the time. It is impossible to keep up, so in order to

assist our customers we offer the option of preset battery types: Flooded, sealed, AGM,

Gel, LiFePO4, calcium and custom. Each type has 2 preset algorithms, for instance: Gel

preset 1 is the USA Gel spec (absorption 14.0V and float 13.7V) and Gel preset 2 is the

Europe Gel spec (absorption 14.4V and float 13.7V). We also provide the charge voltages

related to this cycle. In most cases these are correct; however, if in doubt install on the lower

voltage setting until you have checked with your battery supplier.

- In the event of different battery chemistry types. If you are only using the Pro Charge Ultra

then the lowest battery voltage type must be selected. Never charge a battery on a higher

setting than it should. If you require different battery chemistries then look at our Battery

Chemistry Module (page 5). It allows for different battery chemistry charging .

If a bespoke battery is being used then use the CUSTOM setting. This gives the user the

ability to set their own absorption / float voltages.

- Connect the cables as in the diagram. Ensure that all the terminals are used. In the event of

only one battery being charged, connect the surplus positive output to another used output.

This ensures correct regulation. Failure to do this will reduce the charging performance.

- IMPORTANT: Always connect the cables to the charger first then run them to the batteries.

Never connect to the batteries first and then run to the charger.

Pre setup Mode overview CEC mode (bc) and Power Supply mode (PS)

This Pro Charge Ultra is now constructed with the most power efficient technology available for a

battery charger providing both charging and maintaining capability. This overall design and

efficiency will reduce the overall operating cost of the unit by conserving AC power when it is

not needed. Meanwhile, it provides perfect battery maintenance and overall superior DC

charging performance. The combination of sophisticated hardware and software includes

the detection of the presence of one or more batteries connected to the Pro Charge Ultra.

NOTE: If there is no battery connected, the battery charger will not operate in the new

default bc mode, however this unit can easily adjusted to the older PS mode which will allow

the unit to work in power supply mode. See PS (Power Supply) mode selection below.

Two operational modes, The unit can be used in CEC mode (default ), or PS mode ( needs set)

CEC mode. This is a new ecological regulation brought on by the Californian Energy

Commission (CEC). It is being adopted by more and more states, we feel that it is such a

reasonable regulation that it will eventually be adopted world wide. Essentially, at present,

when you charge your phone and your batteries are full then the charger continues to

operate. This charger uses a small amount off power simply doing nothing. If you multiply

this by millions of households all doing the same thing there is a lot of wasted energy. So, by

turning off the charger you could potentially save numerous power stations. It's a lot more

complex for a marine battery charger which has to charge the batteries then run the boat as

well. However, we have devised a complex algorithm to monitor the power consumption

and when it drops below a certain amount we switch off the charger and transfer the

monitoring to a very low power operational circuit. If, or when, the battery voltage drops a

little our monitoring circuit would recognises this and re-engage the unit. This will maintain

the batteries at a full state and operate as a power pack. If unit is “fired up” with no batteries

connected the charger will read 0.0 0.0 on the front panel. You must have batteries

connected for the unit to activate, if this is not the setting you want then simply set to Power

supply mode ( see below ).

PS mode (power supply). is the way all our chargers have been working up to date, it means the

unit will work even if not connected to a battery bank.

What difference will this make ?

1) It is now legal in California and other adopted states. The CEC mode future proofs.

2) If you power for your system is monitored a reduction in the power used for the equipment

should be noticed ( you can tell you daughter your now green ).

The bottom line as a user on a day to day operation on 99% off installations it will not be a

noticeable feature, it would only prove to be a problem if you want to use the charger as a

power pack. I.e. not connected to the battery banks. In which case, change the mode.

In the event you would like to use your Pro Charge Ultra as a power supply without a battery

in the system you may do so simply by selecting the Power Supply (PS) mode during the

initial startup phase. This mode will allow the charger to be used as a power pack for 12V or

24V (model specific).

Selecting PS (Power Supply) Mode Operation During AC Power On Startup overview

When AC power is applied or when the Self Test function is initiated the numerical displays

will first display “888” to indicate all segments of the displays are working. Then the display

will indicate either “bc” (Battery Charger) or “PS” (Power Supply) for 7 seconds. You can

change the required settings during this time frame if required ( see below for instructions ).

After 7 Seconds the battery charger will default to its “bc” (Battery Charger) mode of

operation or the previously programmed function.

Note: The battery charger will default to the Sealed Battery Type Charge profile (for both “bc” and

“PS” modes of operation). You may also select any of the other battery type profiles in this

mode. See Selecting Battery Type in the programming section of this manual.

If during the AC Power start-up you would like to select the “PS” (Power Supply) mode of operation

you may do so during the 7 seconds window while the display is indicating "bc" by:

1) Push either the or key to toggle between "bc" and "PS"

2) While the display reads "PS" press Setup/Enter

Operating Instructions

From main charge only (not remote control)

On/off the unit can be switched off using the controls on the charger main control panel ( it can

also be switched on/off on the remote ( see later ) )

Unit On press setup and the up button, hold for 5 sec.

Unit Off press setup / enter and down for 5 sec.

The blue AC power LED will flash to show the power is available but the unit is not activated.

SELECTING BATTERY TYPE

To select a battery type/charging profile perform the following:

1. Press and hold the “Setup / Enter” button for 6 seconds, then release the button.

2. The current battery type and Voltage / Amperage displays will flash. The voltmeter

and ammeter will now display voltage, the left hand screen (marked voltmeter) will

show the high charge voltage setting (absorption) and the right hand screen

(marked ammeter) will show the low charge / float / power pack voltage setting.

3. Use the “↑” and “↓” keys to scroll through all the different battery types. The LED

display on the charger in the battery type section will move through the different

types.

4. The voltage and amp readout will display the absorption/conditioning and float

voltages for each profile highlighted.

5. Press the “Setup / Enter” button to confirm selection, the LED will remain solid or

leave for 30 seconds and the selection will be locked in automatically.

ADJUSTING THE CUSTOM BATTERY TYPE SELECTION

WARNING: *Damage can result to your batteries from improper use of this custom setting. Any

damage experienced while using this setting is the responsibility of the user and not

covered by any Sterling warranty. ALWAYS consult the battery manufacturer if you are

unsure of the battery chemistry and charge profile required.

1. Follow above steps and select the “Custom” option on the battery

type display and press enter to enter it.

2. The “Fast charge & Absorption” LEDs will be blinking, indicating you are in the

adjustment mode.

3. The left hand meter will blink and the right hand meter will go out. The numbers on

the left hand meter will be the high voltage setting. Adjust as required by using the

“↑” and “↓” to select voltages up to 15.1V. Press enter when you have selected

the correct voltage. Then right hand screen will flash now flash - this is the float

voltage settings, again, use the arrows to set this voltage and press enter to finish.

NOTE: During this process, real-time voltage and amperages will not be displayed.

SELF TEST MODE

1. Press and hold the “Setup / Enter” and the “↑” and “↓” buttons simultaneously

for 10 seconds then release.

2. The “Self Test” LED will flash until the test is complete.

3. OK or Fault LED's will be displayed, see the Troubleshooting section if the Fault

LED is illuminated.

FACTORY RESET

To return the unit to original factory settings (Sealed Lead Acid)

1. Enter battery type selection as above.

2. Use the “↓” key until you leave the battery type LED panel then the de-sulphation

light will flash, continue to the next setting. The 2 x voltmeters will display “FAC”

“DEF” for factory default.

4. Press the “Setup/Enter” button to confirm selection, the charger will reboot.

EQUALIZATION / DE SULFATION MODE (can only be activated in open lead acid mode)

This mode is only recommended for open lead acid batteries and will only activate when

in open lead acid mode. It can be extremely dangerous to use in other battery

types, as it will over charge the battery to "blow" the sulfation off the plates. This

process generates more gas than normal and, as such, the battery may need

topping up after the process. It is NOT recommended on batteries which cannot be

topped up.

1) Press and hold the setup key for 5 secs then use the or to select

the equalization LED ( while on flooded battery setting ), when selected the LED

will flash.

2) Once selected hold both and for 3 seconds plus, then release.

3) The LED will change from flashing to solid, putting the unit into equalising setting for

240 minutes and remain solid for the full time frame.

4) Once complete, the charger will revert back to the previous charger setting.

POWER LEVEL ADJUSTMENT

1. Hold the“↑” and “↓” buttons simultaneously for about 20 seconds.

2. Volts will display “PL” for Power Level, and the amps 100 for 100%

3. Press the “↓” to adjust the amperage display from 100, 75, 50, 25% output.

4. Press the “Setup/Enter” button to confirm selection.

NOTE: If no action is taken after 15 seconds, the unit reverts to 100% power.

Setup

Enter

Setup

Enter

Setup

Enter

Setup

Enter

Pro Charge Ultra Remote Control

Operation:

Power, Start Up and Language Selection:

a. If breaker is turned on and charger has AC power the remote is lit with the

backlight on.

b. “Language Select: English” (factory default) will display and flash for 5

second. The operator can select the language during these 5 seconds by

pressing the UP or DOWN keys to toggle through all of the available

languages (English, German, Spanish, Italian, French) and then press

SETUP/ENTER key to confirm.

If no selection is made within these 5 seconds, the default language shall be

selected.

(If you wish to change the language at a later date, refer to ‘language selection’

section below).

c. Charger mode will displayed (Charge, Conditioning, Ready) along with voltage

and amperage until another mode is selected.

Button Operation – with AC power applied to the charger

a. (Backlight) Button Operation:

1. Press On-Off for about 1 sec the backlight will turn OFF. Warning

If you hold for more than 4 sec the complete charger will switch off

2. Press On-Off for about 1 sec the backlight will turn back ON.

b. (Alarm) Button Operation:

1. Press Alarm to turn audible alarm OFF.

2. Press Alarm to turn audible alarm ON.

c. (Setup / Enter) Button Operation

***(If not selection is made within 10 seconds charger defaults to prior setting).

1. Press the Setup/ Enter button once

2. This will now allow you to toggle through all available functions using the

↑or ↓

a. Scrolling – (Must push Setup / Enter to confirm) = will

display all of the below one at a time for 4 seconds

automatically scrolling through the menu functions.

b. Charger Name

c. Charger Status (Same display shows both)

i. Mode displaying (Charging, Conditioning or

Ready)

ii. Output Voltage

iii. Output Current

d. Battery Type Selection (Flooded Preset 1)

e. Time to Absorption

f. Run time during this session

g. Current Set Power Level should be 100% unless in Power

Level mode. If a different Power Level is selected the

charger will read 100, 75, 50, 25%.

h. Battery Temperature

i. Charger Temperature

j. Transformer Temperature

k. Faults

i. Over Voltage

ii. Under voltage

iii. Battery Over Temperature

l. Company Information

m. Total Run Time

n. Software Revision

3. Once the remote is displaying the desired function press Setup / Enter

button once to show this functions detail. To change selection repeat

and scroll through to the required information.

d. Button Functions:

Both the ↑or ↓ are used for toggling up and down through the menu options after the Setup/

Enter button has been pressed

Additional Charger Modes

FORCE TO READY/FLOAT Maintenance = “Hold” 10 Seconds

The force to float mode is not necessary for standard operation.

1. Hold the ↓ button down for 10 seconds.

2. The display will stop scrolling and a “Beep” sound to confirm

entered into this mode after button released.

3 The charger will go to float mode and will remain in float until

battery voltage drops to a level where Charge is require or until

power is recycled.

If you do use this function to get out off it you must switch the charger off

at the main AC power source to reset this.

POWER LEVEL ADJUSTMENT = “Hold” 15 Seconds

I. Hold “↑”both “↓” down together for 15 seconds.

II. The display will stop scrolling and a “Beep” sound to confirm entered into this

mode after buttons released.

III.. Press “↓”to adjust the Amperage display from 100, 75, 50, 25% output.

IV. Once Power Level is desired confirm the selection by pushing “Setup/ Enter”.

V. If no actions are taken in 15 seconds the unit reverts to 100% power.

VI. Remote will display Power level at % that is selected (100, 75, 50, 25 for one

second on, then one second off, then on displaying Voltage and Amperage at

that selected power level).

VII. Once a power reduction is selected it remains permanent until re-programmed

again.

VIII. To re-adjust the power level follow steps 1-5 making sure to confirm 100% to

resume normal operation.

IX. When in power level mode selection display (Power Level 50% and output

voltage/ current.

SYSTEM SELF TEST MODE = “Hold” 8 Seconds

I. To test the chargers system hold all three (Setup/ Enter, ↑, ↓) buttons down for

5 seconds,

II. The display will stop scrolling and a “Beep” sound to confirm entered into this

mode after buttons released.

III. The charger will “Self Test” and if normal display “System OK” if not a failure or

failures will be displayed. If more then one failure exists you can push ↑or ↓ to

view the failures.

IV. Press Setup/Enter to go to other functions when complete.

FACTORY RESET = “Hold” 3 Seconds

I. To restore the Factory Defaults “hold” Alarm, Setup/Enter, and ↑, ↓down for 3

seconds.

II. The charger will then restart with the factory defaults.

Output ON/OFF function (For Sterling version only)

a. Press and hold Power button for 4 second to turn the charger

output OFF

b. When charger is OFF, press Power button to turn the charger

output ON

How to change language once a language has been selected or defaulted to English

1. Press and hold SETUP/ENTER key for 3 seconds, the display will go to

language selection mode.

2. Remote will display the current language and flashing for 5 seconds.

3. Select language within these 5 seconds by pressing UP or DOWN key to toggle

through all available language

4. Press SETUP/ENTER key to confirm

5. If no selection is made within these 5 seconds, the language will keep as

default or previous setting unchanged.

6. Remote will go back to normal operation

7. The display sequence of language is English, German, Spanish, Italian, French

IIMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS - this manual contains important safety instructions for the Pro

Charge Ultra

1) Do not expose this unit to rain or snow.

2) Use of attachments not recommended or sold by Sterling Power will void warranty and may

result in the risk of fire.

SHOCK OR PERSONAL INJURY.

3) Do not operate the unit if it has been dropped or visibly damaged in any way

4) Do not disassemble the unit. If service or repair is required please contact Sterling at:

Setup

Enter

Alarm Setup

Enter

Slide parts A to expose screw holes.

For flush mount, remove part B.

For surface mount, keep part B.

After installation, replace parts A.

to install

www.sterling-power.com or www.sterling-power-usa.com

5) To reduce the risk of electrical shock, remove connection to AC shore / station power and

DC connections prior to maintenance or cleaning.

6) Turning off controls WILL NOT reduce this risk.

7) Use of extension cord should not be used unless absolutely necessary. If an extension

cord must be used, make sure:

a) That pins on plug of extension cord are the same number, size and shape of those of the

plug on the charger.

b) That the extension cord is properly wired and in good electrical condition.

c)That wire size is large enough for AC ampere rating of charger as specified in table

(page3)

6) Do not operate charger with damaged cord or plug - replace the cord or plug immediately.

7) Do not operate charger if it has received a sharp blow, been dropped, or otherwise

damaged in any way; take it to a qualified serviceman.

8) Do not disassemble charger; take it to a qualified serviceman when service or repair is

required.

9)To reduce risk of electric shock, unplug charger from outlet before attempting any

maintenance or cleaning. Turning off controls will not reduce this risk.

WARNING – RISK OF EXPLOSIVE GASES.

WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES

GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL BATTERY OPERATION.

FOR THIS REASON IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING

YOUR CHARGER YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS

EXACTLY.

To reduce the risk of a battery explosion, follow these instructions and those published by the

battery manufacturer and any equipment you intend to use in the vicinity of the battery(s).

Carefully review the cautionary markings on this equipment.

SPARK – Be very cautious about dropping metal objects such as screwdrivers and

wrenches onto a battery. This could short-circuit the battery and immediately cause a spark

that may result in a fire or explosion.

REMOVE – All personal metal items such as rings, watches, bracelets, etc. when working

near a battery. A battery can produce a short circuit current high enough to weld a ring or any

other metal causing serious burns.

DRY CELL BATTERIES – Never use the battery charger feature to charge dry cell batteries

that are commonly used with home appliances i.e. a cordless power drill battery. These

batteries may burst and cause injury to persons and damage property.

FROZEN BATTERY – Never charge a frozen battery.

UNPACKING AND INSPECTION – Thoroughly inspect your unit.

11. PERSONAL PRECAUTIONS

a) Consider having someone close enough by to come to your aid when you work near a

lead-acid battery.

b) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or

eyes.

c) Wear complete eye protection and clothing. Avoid touching eyes while working near

batteries.

d) If battery acid contacts skin or clothing, wash immediately with soap and water. If acid

enters eye, immediately flood eye with running cold water for at least 10 minutes and get

medical attention immediately.

e) NEVER smoke or allow a spark nor flame in vicinity of battery or engine.

f) Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or

short-circuit battery or other electrical parts that may cause explosion.

g) Remove personal metal items such as rings, bracelets, necklaces, and watches when

working with lead-acid battery. A lead-acid battery can produce a short-circuit high enough to

weld a ring or the like to metal, causing a severe burn.

h) Use charger for charging a LEAD-ACID battery only. It is not intended to supply power to a

low voltage electrical system other than in a starter-motor application. Do not use battery

charger for charging dry-cell batteries that are commonly used with home appliances. These

batteries may burst and cause injury to persons and damage to property.

12. PREPARING TO CHARGE

a) if necessary to remove battery from vehicle to charge, always remove grounded terminal from

battery first. Make sure all accessories in vehicle are off, so as not to cause an arc.

b) Be sure area around battery is well ventilated while battery is being charged.

c) Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.

d) Add distilled water in each cell until battery acid reaches level specified by battery

manufacturer. Do not overfill. For a battery without removable cell caps, such as valve regulated

lead acid batteries, carefully follow manufacturer’s recharging instructions.

e) Study all battery manufacturer’s specific precautions while charging and recommended rates

of charge.

f) Determine voltage of battery by referring to battery manufactures owner’s manual and make

sure that output voltage selector switch is set at correct voltage. If charger has adjustable charge

rate, charge battery initially at lowest rate.

13. CHARGER LOCATION

a) Locate charger as far away from battery as DC cables permit.

b) Never place charge directly above battery being charged from battery will corrode and damage

charger.

c) Never allow battery acid to drip on charger when reading electrolyte specific gravity or filling bat

t ery.

d) Do not operate charger in a closed-in area or restrict ventilation in any way.

e) Do not set a battery on top of charger.

14. DC CONNECTION PRECAUTION

a) Connect and disconnect DC output clips only after setting any charger switches to “OFF”

position and removing AC cord from electric outlet. Never allow clips to touch each other.

15. FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE/BOAT. A SPARK

NEAR BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARE NEAR

BATTERY.

a) Position AC and DC cords to reduce risk of damage

b) Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.

c) Check polarity of battery posts. POSITIVE (POS,P,+) battery post usually has larger diameter

than NEGATIVE (NEG,N,-) post.

d) Determine which post of the battery is grounded

e) For negative-grounded, connect POSITIVE (RED) clip from battery charger to POSITIVE

(POS,P,+) ungrounded post of battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or

engine block away from battery. Do not connect clip to carburetor, fuel lines or sheet-metal.

Connect to a heavy gauge metal part of the frame or engine block.

g) When disconnecting charger, turn switches to off, disconnect AC cord, remove clip from vehicle

chassis, and then remove clip from vehicle chassis, then remove clip from battery terminal.

h) See operating instructions for length of charge information.

16. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE. A SPARK NEAR THE

BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR

BATTERY:

a) Check polarity of battery posts. POSITIVE (POS, P, +) battery usually has a larger diameter

than the NEGATIVE (NEG,N,-) post.

b) Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, -)

c) Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery.

d) Position yourself and free end of cable as far away from battery as possible - then connect

NEGATIVE (BLACK) CHARGER CLIP to free end of cable

e) Do not face battery when making final connection.

GROUNDING AND AC POWER CORD CONNECTION

a) Charger should be grounded to reduce risk of electric shock. Charger is

equipped with an electric cord having an equipment-grounding conductor and

a grounding plug. The plug must be plugged into an outlet that is properly

installed and grounded in accordance with all local codes and ordinances.

DANGER - Never alter AC cord or plug provided - if it will not fit outlet, have

proper outlet installed by a qualified electrician. Improper connection can result

in a risk of an electric shock.

b) For grounded, cord-connected battery chargers with an input rating less than

15A and intended for use with a global AC input (90V - 270V).

This battery charger is for use with a global AC input (90V - 270V) and has a

grounding plug. A temporary adaptor, as shown (figure is overleaf), may be

used to connect this plug to a two-pole receptacle, if a properly grounded outlet

is not available. The temporary adapter should be used only until a properly

grounded outlet can be installed by a qualified electrician.

DANGER - Before using adapter as illustrated, be certain that center screw of

outlet cover plate screw with a longer screw that will secure adapter ear or lug to

outlet cover plate and make ground connection to grounded outlet.

c) For all other grounded, cord-connected battery chargers:

This battery charger is for use on a circuit having a nominal rating more than

90V (or This appliance is rated more than 15A and is for use on a circuit having a

global AC input (90V - 270V) and is factory fitted with a specific electric cord and

plug to permit connection to an acceptable electric circuit. Make sure that the

charger is connected to an outlet having the same configuration as the plug. No

adapter should be used with this charger.

d) For a permanently connected battery charger:

GROUNDING INSTRUCTIONS - This battery charger should be connected to a

grounded, metal, permanent wiring system; or an equipment-grounding

conductor should be run with circuit conductors and connected to equipment-

grounding terminals or cable on battery charger. Connections to battery charger

provided with a grounding pin:

e) For a direct plug-in battery charger provided with a grounding pin:

CAUTION - Risk of fire or Electric Shock. Connect battery charger directly to

grounding receptacle (three-pong). An adapter should not be used with battery

charger.

f) For a direct plug-in battery charger having a tab for semipermanent

installation: Use only duplex receptacle having center screw; Secure unit in

place by receptacle cover screw; and CAUTION and the following or equivalent:

Risk of Electric Shock or Fire. Disconnect power to receptacle before installing

or removing unit. When removing receptacle-cover screw, cover may fall across

plug pins or receptacle may become displaced.

g) For a commercial battery charger that is intended to be permanently

installed and un-tampered with, the charger should be installed so that it is

not likely to be contacted by people.

DAMAGE – If any parts are missing or damaged, or the unit has been

damaged in shipping contact Sterling, do not take it back to the place of

purchase as we can offer a faster service.

Charger Fault ( Service ) Conditions

LED Label LED Colour Fault

Reverse Polarity Red Indicates a reverse polarity situation

Check DC Connections, ensure positive + ( RED) and negative - (Black and

/ or Yellow) connections are attached accordingly , also check DC fuses,

DC Volts Low Amber DC system V is less than 11V (x2 for 24v)

Wait for battery system voltage to rise over 11.0V and, if not, check and

replace defective batteries.

DC Volts High Red Indicates a high DC voltage from an external

source such as a failed alternator or wind

generator

Using a voltmeter check the voltage at the charger then switch off engine

( stop alternator ) then other charging sources to establish what is causing

the high voltage.

Charger High Temp Amber Charger has shut down due to High temp

Generally this indicates that the unit has been installed in an area of very

high ambient temperature. This unit is designed to be used in a engine room

up to 45-50 Deg C, the unit will operate in higher ambient temperatures but

will reduce it performance off the product, We recommend an ambient off no

more than 50 Deg C. The other possibility is that the internal fan may have

failed, please listen to ensure the fan is running as one would expect the fan

to be on max speed in this fault condition so if quiet this could be the problem.

Check Fan Red Fan Failure

Ensure that the cooling fan can move freely and that no debris is blocking the

fan movement, the fan should come on during the start up sequence to prove

it works, any persistent fan problems may require servicing.

Fault Red Indicates a fault

Possible internal DC fuse blown, Please contact Sterling for service options.

Auto Temp Control Red Flash High Ambient causing power reduction

to sustain output.

See charger high temperature above .

Charger Fault ( Service ) Conditions

LED Label LED Colour Fault

Reverse Polarity Red Indicates a reverse polarity situation

Check DC Connections, ensure positive + (RED) and negative - (Black and

/ or Yellow) connections are attached accordingly , also check DC fuses,

DC Volts Low Amber DC system V is less than 11V (x2 for 24v)

Wait for battery system voltage to rise over 11.0V and, if not, check and

replace defective batteries.

DC Volts High Red Indicates a high DC voltage from an external

source such as a failed alternator or wind

generator

Using a voltmeter check the voltage at the charger then switch off engine

(stop alternator) then other charging sources to establish what is causing