Sterling Power ProCharge Ultra battery charger user manual
Contents
1. Z DANGER HIGH VOLTAGE AVOID SERIOUS INJURY OR DEATH FROM ELECTRICAL SHOCK BEFORE PERFORMING ANY ELECTRICAL WORK TURN OFF AC POWER SUPPLY DANGER EXPLOSION HAZARD AVOID SERIOUS INJURY OR DEATH MAKE CONNECTIONS IN AN ATMOSPHERE FREE OF EXPLOSIVE FUMES Z WARNING LOW VOLTAGE AVOID SERIOUS INJURY FROM ELECTRICAL BURNS AND SPARKS BEFORE PERFORMING ANY ELECTRICAL WORK DISCONNECT ANY DC POWER SUPPLY FROM UNIT CAUTION HOT SURFACES TO REDUCE RISK OF BURNS DO NOT TOUCH WHILE IN SERVICE CHARGE ONLY USER SELECTED TYPE BATTERIES Flooded AGM GEL lithium or Calcium OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE RISK OF ELECTRIC SHOCK NO USER SERVICEABLE PARTS RETURN TO MANUFACTURER FOR SERVICING THIS UNIT IS IGNITION PROTECTED This product requires a knowledge of both a c and d c electrical installation Please do not install or attempt to install this product unless you are qualified to do so All effort is made to make the instructions as Safe as possible but itis not possible to cover all The ultimate battery charger ProCharge U Pro Charge Ukra Sterling Power www sterling power com AC Power www sterling power usa com bu LJ Amps Auto Temp Control 0 Charg MMUNINIIINII 200 er Output Multi Speed Cooling Stand by Battery Health Program Fast Charge m Absorption Float De sulphation CHARGE INFORMATION CHARGER2. By pressing the below sequence on the remote control you can quickly access the most used functions Mv press and hold for 10 seconds to force into Float Mode Ww V press and hold for 15 seconds for direct access to power reduction mode Setu N Vv press these 3 and hold for 5 seconds to start a self test Setu N V press and hold for 3 seconds restores factory defaults SHOCK OR PERSONAL INJ URY 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 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 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 servicem
3. 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 The package should contain the following 1 Charger unit 2 Parts package including a Owners Installation manual b Temperature Probe 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 DO NOT attempt to install or operate the unit if it has been damaged in any way f When disconnecting charger always do so in reverse sequence of connecting procedure and break first connection while as far away from battery as practical g Amarine boat battery must be removed and charged on shore To charge it on board requires equipment specially designed for marine use Exception The instruction manual for a battery charger marked in accordance with exception No 2 to 49 3 and constructed to prevent current flow in excess of 0 1 ampere until the battery is connected with correct polarity followed by the activation o
4. turn off the main A C powi ac Battery Type De sulphation CHARGE INFORMATION DC Output Service DC Low Voltage DC High Voltage Trip High Charger temp trip Lithium LiFePO Calcium tric shock er Do not res Any outputs not being used should be linked across to one that is this is not a requirement for these new models butis good practice as it helps spread loads etc D C 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 amperage rating than the maximum rating of the charger and round it up remember this fuse is primarily protecting the cables and not the product E g a 20 amp charger would have about a 25 amp fuse a 60 amp charger about a 75 amp fuse A full range of fuses and fuse holders are available from Sterling D C fuse 20 larger amperage than charger output 12 or 24 v battery bahk 12 or 24 v battery bahk D C fuse 20 larger amperage than charger output In most installations all these will end up at the same point ie the A C power source should be connect to the boat vehicle chassis for safety The chassis earth will also go there and the D C neg should also go there in effect bonding the total system together ensuring any fault to the chassis will blow a fuse This could vary for steel aluminium boats D C fuse 20 larger amperage than charger output A C
5. 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 gage 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
6. with your purchase Our warranty only covers orders purchased from Sterling Power We cannot accept warranty claims from any other Sterling Power distributor Purchase or other acceptance of the product shall be on the condition and agreement that Sterling Power USA LLC and Sterling Power LTD shall not be liable for incidental or consequential damages of any kind Some states may not allow the exclusion or limitation of consequential damages so the above limitations may not apply to you Additionally Sterling Power USA and Sterling Power LTD neither assumes nor authorizes any person for any obligation or liability in connection with the sale of this product This warranty is made in lieu of all other obligations or liabilities This warranty provides you specific legal rights and you may also have other rights which vary from state to state This warranty is in lieu of all other expressed or implied Sterling Power Products Ltd Sterling Power USA Unit 8 Wassage way Warranty Service Center Hampton lovett ind est 406 Harold Dow Highway Droitwich Suite 4 Worcestershire Eliot ME 03903 ENGLAND WR9 ONX Phone 207 226 3500 Tel 01905 771771 Fax 207 226 3449 Fax 01905 779434 www sterling power usa com www sterling power com
7. 1 Follow above steps and select the Custom option on the battery type display and press enter to enter it 2 The Fast charge amp Adsorption LEDs will be blinking indicating you are in the adjustment mode 4 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 T and J to select voltage up to 15 1V press enter when you have selected the correct voltage then the right hand screen will flash this is the float voltage settings again using the arrows to set this voltage then 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 1 and 4 buttons simultaneously for 10 seconds then release 2 The Self Test LED will flash until the test is complete 3 OKor 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 Flooded Lead Acid 1 Enter battery type selection as above 2 Use the 4 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 re boot POWER LEV
8. EL ADJ USTMENT 1 Hold the tT and J buttons simultaneously for about 20 sec 2 Volts will display PL for Power Level and the amps 100 for 100 3 Press the 4 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 OPTIONAL REMOTE When the optional remote is installed it will display the current status of the charger along with the voltage and amperage 1 The Blue LED is illuminated when the power is ON 2 BACKLIGHT can be set to ON or OFF by toggling the on off button with short sharp action The default is ON 3 To switch the product off hold the button for about 3 seconds and release the unit will shut down to switch back on again simply push the button and the unit will restart 4 ALARM can be silenced or made audible by toggling the ALARM button default is audible PROGRAMMING USING THE OPTIONAL REMOTE Steriing Power Products P kia eo Remote control operation When installing the remote control from new if the charger is already on and you add the remote control the remote will not work you must add the remote control then switch the charger off for 1 min then switch on again to reset the software the charger will then pick up the remote s presence and the remote will work Pressing SETUP ENTER displays SCROLLING 1 using the N a
9. MODE System self test Battery Type Open lead acid Sealed lead acid DC Output Fault DC Low Voltage DC High Voltage Trip High Charger temp trip Lithium LiFePO Check Fan Calcium re Hig capa ing spa expose to rain nor ae way s dis ME eDicc aie fro ehe Tore use Always read the rking on the Kok ide Intended for ib of COMMERCIAL and DOMESTIC u WARNING EN ISO 13297 Small Craft Directive ga by amp AMMA aC ABYC R ROHS am Pera 12V 60A model all other units pro rata b CSA C22 2 107 2 Input voltage range 90 270V 40 70Hz e Power Factor at 230V 0 95 Efficiency 88 5 Full load current 110 230v 10 4 8 Ripple noise R M S 50mV Ground leakage 0 75 mA Generator mains power required to run unit watts electrical safety and installation aspects Sterling can only 12v 20amp approx 300 watts assume a certain basic knowledge is held by the installer 12v 30amp approx 450 watts Top Function 1 11 pre programmed battery curves including LiFePOs 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 PFC active up to 0 99 pf ensuring efficient power conversion up to almost 90 as opposed to about 50 for older non PFC technology 12v 40 amp approx 600 watts 12v S50 amp approx 750 watts 12v 60amp approx 900 watts 24v 20amp approx 600 watts 24v 30amp a
10. ally controlled based on battery chemistry selected Automatically selects between Boos Charge Absorption Conditioning and Float Ready MAINTENANCE This unit is solid state software controlled and requires no constant adjustments or attention however the following items should be checked On start up ensure the panel shows no fault LEDs On start up check the conditions of the fuses and ensure there is no discolouration or corrosion round the fuse also that the breaker will manually trip and reset On start up check the fans cooling flow is not impede by debris keep the area round the unit clear of items and dirt On Start up check for any traces of water other liquids running down the front off the unit or any evidence of this water stains Do not use the charger find the leak and fix the leak or remount the charger to a safer place away from the water source Check the battery charger terminals and the battery terminals for corrosion monthly clean as required As per battery manufactures instructions check and top up the batteries with distilled water as required monthly Do not use tap or bottled water as this will destroy the batteries Check the wires for any burning or chaffing where the wires pass through bulkheads monthly Repair replace as required When the charger is on feel the temperature of the batteries they should not be noticeably hotter than the surrounding ambient temperature If the batteries are h
11. am Es 12 v 50 60 3 di p ES v 50 60 amp ae IMENSIONS 24 v 20 amp i 24 v 30 amp L r o i In inches E and mm ES ee e BS os o a F 9 p N Cut out fy lt 90 x 62 mm K 2 DOD _ s eis 34 90 WA Y my ERG j 215mm D 8 inch l Qo o aN N A 5 lt FLAL Oeae lt JO 89 215 i D 7 7 u3 f i 34 90 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 itis 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 A C 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 Flood
12. an 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 ALEAD 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 cau
13. ed sealed AGM Gel LiFeP O4 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 types of batteries the lowest battery voltage type must be selected Never charge a battery on a higher setting than it should 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 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 Setu Unit On press setup and the up button hold for 10 sec N Setu Un
14. ed power available available on local ensure that they do not play with the control or remote control panel appliance 19 Conforms to A B Y C drip test is water proof from water directly dropped on to the top of the unit 17 deg if installed correctly vertically 20 The printed circuit boards are conformal coated for high humidity operations and drawing on a vertical bulkhead Installation Install in cool dry well ventilated space This product has a high heat tolerance and can be installed in a engine room This product is ignition protected and can be installed near the batteries Charger MUST be installed vertically to allow for convection air flow and also in the vertical position the product is drip proof The product will work in any position but we cannot guarantee the drip proof aspect in any other position IN Quick LED feature guide oC barda Urra 15 hee She ee Nee aaa a 10 11 3 E www steiN pg power co Multi Speed Cooling rout To avoid serious injury or death from electric shock Before opening turn off the m en Sterling Power a www sterling e A r Ower uga AC Power m Auto Temp Contro Active PFC Stand by ET RR Fast Charge System self test i Buiphation c HAR Battery Type OK m N Open lead acid DC Qyifftit Servicg Sealed lead acid DU Loyss ftage A G M 4R High Voseg Trip GEL a Charger toy Lithium LiFePO ECK Fan Calci
15. f a manually operated control Attach at least a 24 inch long 6 guage AWG insulated battery cable to NEGATIVE NEG N battery post Position yourself free end of cables as far away from battery as possible then connect NEGATIVE BLACK charger clip to free end of cable Break first connection while as far away from battery as practical GROUNDING AND A C 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 FIG RHS of page 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 o
16. fans have failed 23 Check fans fans are thought to be defective 24 Case screws to access the wiring of the product Battery type Preset information for 24 v x all voltages by 2 Preset 1 Preset 2 Battery type Absorption Rough guide time factor Charge Float Charge Float only 14 8 13 6 14 7 13 4 Flooded open lead acid 8 14 4 13 6 14 6 13 4 Sealed lead acid 10 14 35 13 35 14 6 icone AGM 9 14 0 13 7 14 4 13 8 Gel 10 14 8 14 4 14 6 14 4 Lithium LiFePOs 8 15 1 13 6 Custom set Calcium Custom 8 15 5 15 5 15 5 15 5 De sulphation Equalization NA Minimum Maximum absorption absorption time mins time mins 60 600 360 720 60 480 600 1200 240 480 60 360 240 240 Pro Charge Ukra Sterling Power S 3 GLOBAL A C Input amp Active Power Factor Correction Ground bonding earthing This is extremely important and often overlooked there are in effect 3 grounds 1 the earth wire A C 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 D C negative Ground Chassis Boat grounding Ee www sterling power com AC Power I Auto Temp Control I g b Volts G Active PFC 0 Multi Speed Cooling Chai Stand by www sterling power usa com b D Amps MILII 200 rger Output Battery Health Program Fast Charge Absorption Float CHARGER MODE S o AC circuit breaker s injury or death from elec
17. 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 The package should contain the following 1 Charger unit 2 Parts package including a Owners Installation manual b Temperature Probe 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 DO NOT attempt to install or operate the unit if it has been damaged in any way FEATURES vV AUTOMATIC GLOBAL AC INPUT This unit has been designed for 110 240 VAC operation at 60Hz US and 50Hz European V POWER FACTOR CORRECTION This ensures efficient operation of the unit regardless of the quality of the power input V MULTIPLE BATTERY TYPE CHARGING CAPABILITY User selected battery types including new technologies such as Lithium Lifep04 vV SELECTABLE POWER LEVEL Adjust the amperage draw of the unit to prevent it from competing with other appliances when only a lower amperage shore station power hookup is available vV FULLY AUTOMATIC Charge rates and battery maintenance automatic
18. from the date of manufacture Our warranty covers manufacture and material defects Damages caused by abuse neglect accident alterations and improper use are not covered under our warranty Warranty is null and void if damage occurs due to negligent repairs Customer is responsible for inbound shipping costs of the product to Sterling Power either in the USA or England Sterling Power will ship the repaired or warranty replacement product back to the purchaser at their cost If your order was damaged in transit or arrives with an error please contact us ASAP so we may take care of the matter promptly and at no expense to you This only applies for shipping which was undertaken by our company and does not apply for shipping organised by yourself Please do not throw out any shipping or packaging materials All returns for any reason will require a proof of purchase with the purchase date The proof of purchase must be sent with the returned shipment If you have no proof of purchase call the vendor who supplied you and acquire the appropriate documentation To make a claim under warranty call our customer care line at USA 1 207 226 3500 England 01905 771771 We will make the best effort to repair or replace the product if found to be defective within the terms of the warranty Sterling Power will ship the repaired or warranty replacement product back to the purchaser if purchased from us Please review the documentation included
19. installation input to charger Wiring using ring or captive spade connections and a proper crimping tool attach the A C 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 metre and protect from sharp edges when passing through bulkheads and all other openings as per any standards which apply to the installation 12 or 24 v battery bahk AC BREAKING SIZE AC input rating AWG Cable length Charger Model 110 Volt 220 Volt 25ft 50ft 100ft 150ft Breaker Breaker 7 6m 15 2m 30 5m 45 6m PCU1210 2 Output 6 Amp 4 Amp 18 16 14 12 PCU1215 3 Outputs 7 Amp 5 Amp 18 16 14 12 PCU1 220 3 Outputs 8 Amp 6 Amp 18 14 12 10 PCU1230 3 Outputs 11 Amp 7 Amp 16 14 10 8 PCU1 240 3 Outputs 14 Amp 8 Amp 16 12 10 8 PCU1250 3 Outputs 16 Amp 10 Amp 14 12 8 8 PCU1260 3 Outputs 16 Amp 10 Amp 14 12 8 8 PCU2420 3 Output 14 Amp 8 Amp 16 14 10 8 PCU2430 3 Outputs 14 Amp 8 Amp 16 14 10 8 10 amp Length of conductor cable to and from power source D C installation output from charger Distance 3m 10 ft 5m 15ft 7m 22ft 8m 25ft 9m 30ft AWG 14 12 10 10 10 Choosing cable unlike A C conductors D C are very sensitive to 15 amp voltage drop The longer the cable runs the larger the cable s thickness needs to be ensure only quality fire retardant cableis Distance 3m 10ft 5m 15ft 7m 22f
20. it Off press setup enter and down for 10 sec vV The blue A C 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 over 10 seconds then release the button 2 The current battery type and Voltage Amperage displays will flash The voltage and ammeter will now display voltage the left hand screen marked voltmeter will show the high charge voltage setting and the right hand screen marked ammeter will show the low charge float power pack voltage setting 3 Use the T and 4 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 Volts and Amps readout will display the charge 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 ADJ USTING THE CUSTOM BATTERY TYPE SELECTION NOTE Damage can result to your batteries from improper use of the 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
21. it on constant current mode 10 OK unit operating within normal parameters 11 Fault fatal fault needs 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 plus down button for 5 sec On select button plus up button for 5 sec 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 Lithium battery Use this charger must not be used to charge lithium battery cells by itself you cannot charge lithium cells on there own you must have a lithium balancing device in conjunction with the charger sulphation cycle 16 Absorption charger on initial charge cycle 17 De sulphation cycle operational 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 D C 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
22. nd v directional keys scroll through the below menu items 2 Pressing SETUP ENTER E Enter scroll mode and it will display automatically each option every 10 seconds or you can use the arrow buttons to speed up the scroll time if you need to get to information faster Using the directional keys again will display additional options to be selected press SETUP ENTER when done 1 Charger name displays charger model 2 Charger status displays charging absorbation float status 3 Battery type selection scroll through the battery types 4 Time to absorption displays the time left in absorption mode 5 Run Time displays units total running time 6 Power Level displays current output power levels allows for power reduction in this screen push enter again to power reduce 7 Charger temperature 8 Battery temperature displays battery temperature 10 Transformer temperature displays the transformer temperature 11 Faults displays any faults active or simply No faults displayed 12 Company information 13 Total run time 14 Software version the installed software version Sr SNA SA SMA IMPORTANT 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 LLC will void warranty and may result in the risk of fire Remote control short cuts
23. orrect crimping tools are used D C 12 or 24V 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 PCU 12V 30 60A amp Earth European sensor to the position Live Neutral 24V 20 30A have bolt as shown connect the Live Neutral Ground USA terminals as depicted above sensor end to the neg stud rather than screw terminals terminal on one of the batteries 1 2 3 Common Negative which you think will be in the hottest environment red red red Black Europe Yellow USA Pos terminals on 3 x battery banks 73 198 198 mm 7 3 4 inch kL rT Ny f 12 v 10 40
24. ot to the touch then they need major investigation check the charger voltage is within parameters If it is then the battery s must be checked as they are probably defective Never walk away from warm hot batteries as there is a major problem switch the charger off Grounding Methods COVER OF GROUND D IT LET BU _ GROUNDING 7 AE as GCeQUADING PIN There is a 2 year return to factory warranty with all Sterling products Contact Sterling in Europe or USA www sterling power com www sterling power usa com STERLING WER Your 100 satisfaction is our goal We realise that every customer and circumstance is unique If you have a problem question or comment please do not hesitate to contact us We welcome you to contact us even after the warranty and return time has passed Customer Service amp Warranty Product Warranty Each product manufactured by Sterling Power comes with at least a 2 year limited factory warranty Certain Products have a warranty period of time greater than 2 years Each product is guaranteed against defects in material or workmanship from the date of purchase At our discretion we will repair or replace free of charge any defects in material or workmanship that fall within the warranty period of the Sterling Power product The following conditions do apply The original receipt or proof of purchase must be submitted to claim warranty If proof cannot be located a warranty is calculated
25. pprox 900 watts volt metre accuracy 1 5 amp metre accuracy 1 6 New synchronised rectification output as opposed to diode output giving up to an extrai0 Tested to CE standards 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 experienced by the customer even though the new extreme efficiency reduces the need for fans at high ambient temperatures 40 50 deg C fans would still be required to ensure operation 11 Primary processor digitally controlled and an emergency backup secondary analogue aie Ef controlled high voltage trip 12 32 LED information pane 3 Internal scan and systems check 14 Remote control 5 Small footprint and light weight 6 Include battery temperature sensor EN61000 3 2 EN61000 3 3 EN55014 1 EN 55014 2 EN60335 2 29 This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision of instruction concerning use of the appliance by a person responsible for their safety 17 As with all our marine chargers no exposed ferrous metals used only aluminium stainless steel copper brass gold exposed to air Children should be supervised to 18 power reduction to allow unit to work with restrict
26. se 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 burs
27. t 8m 25ft 9m 30ft used AWG 12 10 10 8 8 20 amp Distance 3m 10 ft 5m 15ft 7m 22ft 8m 25ft 9m 30ft AWG 10 10 8 6 6 IMPORTANT 30 amp The closer to the batteries you fit the charger the better Not only do you save expensive cable you also get better performance from Distance 3m 10 ft om 15ft m 22ft 8m 25ft 9m 30ft the charger AWG 10 8 6 6 4 The cable should be properly rated 105 deg C fire resistant do not 40 amp use solid cable or speaker wire Distance 3m 10 ft 5m 15ft 7m 22ft 8m 25ft 9m 30ft AWG 8 6 6 4 4 50 amp Distance 3m 10 ft 5m 15ft 7m 22ft 8m 25ft 9m 30ft AWG 6 6 6 4 2 60 amp Distance 3m 10 ft 5m 15ft 7m 22ft 8m 25ft 9m 30ft AWG 6 4 4 2 2 There is a 2 year return to factory warranty with all Sterling product Contact Sterling in Europe or USA www sterling power com www sterling power usa com Remove the 2 screws on the bottom of the front cover marked number 24 on the previous pages quick guide a this will reveal the main wiring area i E rir AN w4 High Voltage Ly A A A C cover plate i z and clamp Sa PCU 12V 10A amp 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 Remove the 2 screws on the A C area and the 3 screws on the D C clamps to enable the appropriate wires to be attached A C input 90 270 volts A C Ensure secure connections and c
28. t 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 battery d Do not operate charger in a closed in area or restrict ventilation in any way e Do not set a battery on
29. um Lithium must be used in conjunction with a ithit ium balancing system High current capable of causing sparks burns and fires ain A C power Do not expose to rain nor always disconnect the D C cables from the eae before 16 17 18 19 20 21 22 23 924 14 To Fit in accordance with UL specification and to ensure products complies wit the Drip test fit this way up as per the label 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 A C power shows the a c power is connected and the product is live 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 charge curve 6 Shows that the active PFC power Factor Correction is active 7 Fan speed control varies depending on temp 3 spray Replace defective wires cords before use Always read the working on the D C side Intended for both CO i manual before operating the charger and DOMESTIC use ttt sae Tt speeds 8 Standby charger power system power requirement very low unit on low float voltage to prolong battery life 9 Fast charge un
30. utlet 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
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